There’s a reason people buy toolboxes. While each tool serves its purpose, having only one at your disposal vastly limits what you’re able to achieve. On the other hand, having all your tools allows you to do more and solve a wider range of problems.
Similarly, no maintenance team or plant manager should look to just one maintenance KPI to track and improve production. Multiple maintenance metrics—and categories of metrics—exist because each one provides different information that leads you to take several different actions.
Today, we’re going to take a look at Total effective equipment performance, or TEEP, and how your maintenance team can use it together with OEE and OOE to improve scheduling and output at your company.
What is TEEP?
Total effective equipment performance (let’s call it TEEP from now on) exists in the same family of maintenance metrics as overall equipment effectiveness (OEE) and overall operations effectiveness (OOE). All three metrics take machine performance, quality, and availability into account to measure overall equipment performance. Where these metrics differ lies in how they define availability.
On its own, TEEP measures your total potential for equipment capacity. It defines availability as a function of all available time—365 days a year, 7 days a week, 24 hours a day. When you measure TEEP, you’re asking, “How much could we potentially be producing if there were no limits to scheduling?”
TEEP is calculated by multiplying performance, quality, and availability, where availability is defined as current production time divided by all available time.
For example, if you ran a machine 24/7 for a week and it produced perfect products without stopping once, TEEP would be 100%. If that same machine ran 16 hours a day without stopping, availability would be 67% (16 hours divided by 24 hours). Let’s say it also operated at 90% of potential throughput (performance) and produced perfect products 88% of the time (quality). The asset’s TEEP would be 53% (0.9 x 0.88 x 0.67).
Of course, no plant is ever running on a 24 hours a day, 365 days a year schedule. This is why TEEP is useful when compared to the other metrics in its family.
How TEEP compares to OEE
As a metric, TEEP is most closely related to OEE, so let’s distinguish between these two metrics first.
While TEEP measures an asset’s potential capacity, OEE measures an asset’s current level of productivity. It’s calculated, much like TEEP, by multiplying an asset’s availability, performance, and quality, where availability is calculated as the total run time of the asset divided by the planned production time of that asset.
OEE differs from TEEP in that it is rooted in the reality of the current production schedule. It supposes that the maximum amount of time that a piece of equipment can run cannot be greater than what it already is.
Because OEE is a current-state metric, it gives production teams and operators a pretty accurate read on how well their equipment is performing, and whether any changes to availability, performance, or quality could increase capacity. Because OEE is closely tied to production, it’s a metric that many facilities monitor in real-time to determine whether any improvements could be made.
How TEEP compares to OOE
Similar to TEEP and OEE, OOE (overall operations effectiveness) is once again calculated by multiplying performance, quality, and availability, where availability is defined as actual production time divided by operating time.
Operating time includes the planned production time of an asset (like OEE), plus any unscheduled time during which an asset might be taken offline.
How to use TEEP
Now that we have these metrics—and the differences between them—straight, let’s talk about how they can be used together. We can think of these three metrics as a sort of cascading system, where TEEP measures the total effective (or potential) equipment performance, OOE measures your current equipment performance taking unscheduled time into account, and OEE measures everything as it is right now.
We spoke to Stuart Fergusson, Director of Solutions Engineering at Fiix, to parse out these three scenarios. “TEEP is a couple of steps removed from a true maintenance metric,” he says. “It’s useful at the business level for someone like a plant manager because it helps inform scheduling decisions.”
In other words, calculating TEEP helps you answer questions like, “Should we introduce new shifts? Is it worth it to run through the holidays? What would happen if we ran through weekends?”
Stuart adds that some people are quick to jump to metrics like TEEP because they’re actually not calculating OEE correctly. This happens when maintenance is done during downtime is not counted against OEE. As an example, think of a factory that shuts down during weekends and runs all maintenance during that time. Maintenance time is not being counted against production here, which could give you an inflated sense of what your OEE actually is. If maintenance is counted as planned downtime, you get a very different sense of your OEE and what you’re actually capable of achieving.
Take this example: Let’s say that you calculate your OEE as 90% based on the 5 days a week that your machinery runs. With an OEE that high, it seems like it would be simple to increase capacity without buying any new equipment. But what if you use the downtime on weekends to run all your routine maintenance? That time is not available for more production, because it’s always being blocked off for maintenance, but it’s throwing off your OEE because it’s not being included in the equation.
Stuart suggests calculating OEE, OOE, and TEEP the way you normally would, and then examining the deltas between each metric. By investigating the differences between each metric, you can start to see where changes in scheduling could be made to improve production.
“You could be running your equipment very, very well three days a week, and you would still get a low TEEP score,” he says. “But compared with OEE, you can look at that delta and say, ‘We would have to add X staff members to improve our OEE.’”
How TEEP can help you plan
TEEP can be improved when performance, availability, or quality improvement, and it’s probably most useful when you’re out of ideas for how you could improve your OEE given your current production schedule.
TEEP can be used as a benchmark to compare how you’re currently planning your plant production schedules. Unlike OEE and OOE, it gives you an idea of how much your equipment is sitting unused. Again, Stuart warns that its usefulness has its limits. “You should only ever be tracking and putting a metric in front of people that have the ability to change it,” he says. “There’s nothing an operator can do to affect the total available time. On top of that, they can’t schedule themselves in for another shift.”
But when operators, maintenance teams, and plant managers work together (yes, you’ve heard this before with regards to total productive maintenance), it’s clear how they can use their own metrics (like MTTR for maintenance) to improve overall equipment production capacity. When these functional areas can work together to improve capacity while taking the realities and limitations of the entire operation into account, a holistic picture starts to emerge of what a plant is truly capable of achieving.