"What gets measured gets managed." — Peter Drucker.
"What gets measured manually gets manipulated." — Modern Manufacturing Reality.
Every factory tracks OEE (Overall Equipment Effectiveness).
It is the gold standard. But OEE is a Scoreboard. It tells you that you lost the game yesterday. It doesn't tell you how to win today.
If you want to drive continuous improvement, you need to look beyond the top-line score. You need to measure the health of the system that produces the OEE.
Here are the 7 KPIs that differentiate World-Class Manufacturers from the rest, and why you need more than a spreadsheet to track them.
What it is: Did we run what we planned to run, when we planned to run it?
Why it matters: Low compliance creates chaos. It forces Maintenance to defer PMs and Logistics to expedite shipping.
The Fabrico Fix: Use the Interactive Planning Board to visualize conflicts. If you hit 95% Schedule Compliance, OEE usually follows.
What it is: The ratio of Planned Work (PMs/PdM) vs. Unplanned Work (Emergency Repairs).
Why it matters: It costs 4x more to fix a machine after it breaks. World-Class is >80% Planned. Most factories are <40%.
The Fabrico Fix: Automate PM triggers based on PLC Cycle Counts. Don't rely on memory; let the machine call for help before it breaks.
What it is: The average time from "Machine Stop" to "Full Speed."
Why it matters: This measures your Maintenance team's efficiency. A high MTTR usually means technicians can't find parts, manuals, or the root cause.
The Fabrico Fix: Use Fabrico Assistant (AI) to instantly find troubleshooting guides and Video Analysis to identify the root cause faster.
What it is: The number of stops under 2 minutes per shift.
Why it matters: Operators often ignore micro-stops, but they destroy flow. 50 stops of 1 minute = 50 minutes of lost production, plus 50 ramp-up losses.
The Fabrico Fix: Connect to the PLC. Humans won't log micro-stops. The software must capture them automatically to show the true "Death by a Thousand Cuts."
What it is: The percentage of time a technician spends actually fixing machines (vs. walking, searching for parts, or doing paperwork).
Why it matters: Industry average is only 35%. Increasing this to 50% is like hiring free technicians.
The Fabrico Fix: Mobile Execution. Give technicians the app. If they can scan a part and close a work order at the machine, they spend less time in the office.
What it is: The percentage of product that is good without rework.
Why it matters: Rework is the "Hidden Factory." It consumes capacity without adding revenue.
The Fabrico Fix: Link Maintenance to Quality. If FPY drops, automatically trigger a "Calibration Check" on the machine.
What it is: How often you rotate your spare parts stock.
Why it matters: Low turnover means you have "Dead Capital" sitting on the shelf (obsolete parts). High turnover with stockouts means you are too lean.
The Fabrico Fix: Use AI-Driven Min/Max Levels (Roadmap) to right-size inventory based on actual consumption data, not gut feel.
You can calculate these KPIs in Excel once a month. That is "Reporting."
Or, you can track them in real-time. That is "Management."
The difference between a struggling plant and a profitable one isn't the machines; it's the Reaction Time to these metrics.
Don't just watch the scoreboard. Manage the game with Fabrico.
Leading vs. Lagging: OEE is a lagging indicator (the result). To change the result, you must track Leading Indicators (the behaviors), such as Planned Maintenance Compliance and Schedule Adherence.
The "Vanity Metric" Trap: Tracking 50 KPIs means you are tracking nothing. Successful plants focus on a "Vital Few" metrics that align Production, Maintenance, and Quality.
Automation is Mandatory: If you calculate these KPIs manually at the end of the month, they are useless. You need Real-Time Data to spot trends while there is still time to react.
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