Enter Production Data
Use the form below to measure speed losses and missed throughput inside a manufacturing process.
Example Data Table
This sample shows how the analyzer can highlight missed output and speed loss.
| Metric | Example Value |
|---|---|
| Planned Production Time | 480 min |
| Unplanned Downtime | 45 min |
| Operating Time | 435 min |
| Ideal Cycle Time | 30 sec/unit |
| Actual Units Produced | 750 units |
| Rejected Units | 18 units |
| Good Units | 732 units |
| Ideal Output | 870 units |
| Performance Rate | 86.21% |
| Performance Loss | 13.79% |
| Lost Units | 120 units |
| Lost Time | 60 min |
Formula Used
1) Operating Time
Operating Time = Planned Production Time − Unplanned Downtime
2) Ideal Output
Ideal Output = (Operating Time × 60) ÷ Ideal Cycle Time
3) Performance Rate
Performance Rate (%) = (Actual Units Produced ÷ Ideal Output) × 100
4) Performance Loss
Performance Loss (%) = 100 − Performance Rate
5) Lost Units
Lost Units = Ideal Output − Actual Units Produced
6) Lost Time
Lost Time (min) = (Lost Units × Ideal Cycle Time) ÷ 60
7) Quality Rate
Quality Rate (%) = (Good Units ÷ Actual Units Produced) × 100
8) Estimated OEE
Estimated OEE (%) = Availability × Performance × Quality
How to Use This Calculator
Enter the total planned production minutes for the shift or job.
Enter only unplanned downtime, not lunch or scheduled breaks.
Add the ideal cycle time in seconds per unit.
Enter the actual units produced during the operating period.
Enter rejected units to separate good output from total output.
Optionally add a planned target to compare expected throughput.
Click the analyze button to view loss percentages, missed units, and charted performance.
Use the CSV or PDF buttons to share the output.
Frequently Asked Questions
1) What does performance loss mean in manufacturing?
Performance loss shows how much output was missed because the process ran slower than its ideal cycle rate during actual operating time.
2) Is this the same as downtime loss?
No. Downtime loss removes available run time. Performance loss measures reduced speed while the equipment was still running.
3) Why is ideal cycle time important?
Ideal cycle time defines the best expected speed for one unit. It becomes the reference point for calculating ideal output and speed loss.
4) What if performance rate is above 100%?
A value above 100% usually means the ideal cycle time is too slow, downtime is overstated, or production counts need review.
5) Should rejected units affect performance?
Rejected units do not reduce performance rate directly here. They are used for quality rate, which helps estimate the broader efficiency picture.
6) Can I use this for line balancing reviews?
Yes. The cycle gap, lost time, and missed units can quickly show whether a workstation or machine is constraining throughput.
7) What is the benefit of target attainment?
Target attainment compares actual output with the production goal. It helps supervisors separate schedule misses from pure speed losses.
8) When should I download the report?
Download the report after each shift, changeover, or job run so performance trends can be shared and compared consistently.