Workbook

OEE loss diagnosis workbook

Interactive, step-by-step workbook to quantify, validate, root-cause, and prioritize your top availability, performance, and quality losses. Designed for cross-functional kaizen sprints and operator-centered experiments — captures evidence, owners, containment actions, experiment plans, and measured results.

Interactive Tool

OEE loss diagnosis workbook

Purpose

This interactive workbook helps your team capture the top OEE losses, validate the data, record root-cause hypotheses with evidence, and turn the highest-value opportunities into short experiments with clear success criteria. Run this after a baseline OEE measurement and use it with a cross-functional team for focused improvement sprints.

How to use

Enter baseline OEE and team context.
List your top losses (up to five). For each loss, record measurement, data source, validation checks, root-cause hypothesis, evidence, owner, containment actions, and an experiment idea.
Score expected impact (1–10) and ease (1–5) to prioritize—calculate a manual priority score or use the prioritization notes to decide.
Plan short experiments, record results, and update the workbook. Repeat until the loss is reduced to an acceptable level.

Use concise, evidence-based entries. Avoid vague descriptions — include timestamps, data sources, and tangible measures whenever possible.

Baseline measurement date

Date or date range for the baseline OEE measurement (e.g., 2026-08-01 to 2026-08-07)

Baseline OEE (%)

Overall baseline OEE as a percentage (e.g., 62.5)

Baseline Availability (%)

Portion of scheduled time available (e.g., 85)

Baseline Performance (%)

Speed efficiency (e.g., 92)

Baseline Quality (%)

Good parts portion (e.g., 99.5)

Team & context (who's in the room, line, shift, product)

List participants, line/area, shift, and product or process being examined.

Top losses (slot-based)

Fill each Loss slot for your top 1–5 losses. Use precise names (e.g., 'Changeover delay', 'Motor failure', 'Operator adjustment', 'Quality: burrs causing rework').

Loss 1 — name

Short descriptive name

Loss 1 — category

Loss 1 — measured value

Minutes lost or percent lost. Also enter units in the next field.

Loss 1 — units

Loss 1 — data source

Where this number comes from (MES, shift log, timestamped observation, operator count)

Loss 1 — data validated?

Quick validation: Have you checked source timestamps, sensor logs, or operator logs?

Loss 1 — root-cause hypothesis

State your best-root cause hypothesis in one sentence (e.g., 'Changeover takes extra 12 minutes due to missing tools and non-standard sequence').

Loss 1 — evidence

Attach or describe concrete evidence: timestamps, photos, error codes, witness names, sample parts, trending data.

Loss 1 — owner (who will own the experiment)

Name and role of the person accountable for running the containment and experiment.

Loss 1 — containment actions (short-term)

Immediate actions to contain the loss while you test experiments.

Loss 1 — experiment idea

A short, time-boxed experiment you can run in hours or days (not a long project). Include the change, how you'll apply it, and how long it will run.

Loss 1 — expected impact (1-10)

Estimate how big the impact would be on the loss if the experiment succeeds (1 = tiny, 10 = game-changer)

Loss 1 — ease of implementation (1=hard, 5=easy)

Rate how easy and low-risk the experiment is to run

1.0 10.0

Loss 1 — manual priority score

Optional: compute Impact x Ease or another formula locally and enter the priority number to sort your list.

Loss 1 — ready to run experiment?

Quick check: data validated, owner assigned, experiment defined.

Loss 2 — name

Loss 2 — category

Loss 2 — measured value

Loss 2 — units

Loss 2 — data source

Loss 2 — data validated?

Loss 2 — root-cause hypothesis

Loss 2 — evidence

Loss 2 — owner

Loss 2 — containment actions

Loss 2 — experiment idea

Loss 2 — expected impact (1-10)

Loss 2 — ease (1-5)

1.0 10.0

Loss 3 — name

Loss 3 — category

Loss 3 — measured value

Loss 3 — units

Prioritization notes (matrix guidance)

Use this field to record which losses you prioritized and why (e.g., 'Loss 1 selected: high impact, low effort; Loss 2 deferred: requires capital spend').

Experiment log (up to 3 experiments)

Record the short experiments you run against prioritized losses. Keep entries concise and evidence-focused.

Experiment 1 — date

YYYY-MM-DD

Experiment 1 — target loss (e.g., Loss 1)

Reference the loss slot name

Experiment 1 — brief description

Experiment 1 — hypothesis

If we do X, then Y will happen because...

Experiment 1 — method

How you will run the experiment, sample size, duration, controls

Experiment 1 — success criteria

Quantifiable success criteria (e.g., reduce changeover by >= 6 minutes or reduce scrap by 50%)

Experiment 1 — result summary

Experiment 1 — owner

Experiment 2 — date

Experiment 2 — target loss

Experiment 2 — brief description

Next steps & facilitator notes

Record follow-ups, required approvals, training, or items requiring deeper investigation.

Recommended cadence for follow-up

Confidential?

Is the content confidential or restricted to this team?

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OEE loss diagnosis workbook