Crushing the Six Big Losses: Why Your OEE Score is Only Half the Battle

What are the Six Big Losses in OEE?

The Six Big Losses are a framework used to categorize the most common causes of manufacturing inefficiency: Equipment Failure, Setup and Adjustments, Idling and Minor Stoppages, Reduced Speed, Process Defects, and Reduced Yield.

In a standalone OEE system, these are just numbers on a chart.

Fabrico is a cloud-based MES and OEE platform for manufacturers, with maintenance management (CMMS) built in, so these losses become the triggers that drive your maintenance and production teams to act.

Availability Losses: Equipment Failure and Setup Time

Availability losses occur when a machine is scheduled for production but is not running due to unplanned breakdowns or changeovers.

For Mike (the Tactical Manager), equipment failure is a problem of turning data into action.

If a machine stops, Fabrico’s OEE module detects the signal via PLC and instantly sends a Smart Notification to the technician’s mobile device.

By using QR Code scanning, the technician accesses the exact SOPs and parts list needed, slashing the Mean Time to Repair (MTTR).

To reduce Setup and Adjustment losses, the Interactive Planning Board uses real-time data to optimize changeover sequences, ensuring the line returns to full speed faster.

Performance Losses: Minor Stoppages and Slow Cycles

Performance losses are the "Silent Killers" of the Hidden Factory, representing moments when the machine is running but not at its rated speed.

Idling and minor stoppages (micro-stops) are often too short for operators to log manually.

Fabrico uses Computer Vision (Inefficiencies Zoom-In) to capture visual evidence of these micro-stops.

This allows managers to "Zoom-In" on the footage to determine if the loss was caused by poor material quality or a mechanical misalignment.

Instead of guessing why the line is running at 85% speed, the system provides the data needed to stabilize the cycle and reclaim lost capacity.

Quality Losses: Process Defects and Startup Yield

Quality losses represent the time spent producing scrap or parts that require rework.

Maintaining high OEE Quality scores requires a strict adherence to Standardized Work and Digital CILs (Clean, Inspect, Lubricate).

If the OEE software detects a spike in scrap, it often correlates with a missed maintenance task or a "dial twiddling" operator adjustment.

Fabrico’s digital checklists ensure that every operator follows the "Centerlining" best practices aligned with ISO 9001 or IATF 16949 standards.

By connecting Quality data to Maintenance execution, you ensure that "Good Machines make Good Parts."

Comparison Matrix: Solving the Six Big Losses

The Strategic Result: Engineering Uptime

For Paula (the Strategic Leader), the goal is to transform the factory from reactive firefighting to proactive engineering.

When your OEE and CMMS are synchronized, you aren't just measuring how much money you lost; you are investing in the systems that prevent those losses from recurring.

This integrated approach reduces the Maintenance Cost per Unit and protects the high-value assets that drive your enterprise revenue.

Stop watching your losses. Start automating your gains.