OEE formula simulator — Bogie Press 3Live calculation
OEE = Availability × Performance × Quality
78.3%
OEE benchmarks
World class OEE> 85%
Typical industry60 – 85%
Improvement needed< 60%
Bogie Press 3 — today78.3%
Bogie Press 3 — this week avg81.6%
HVAC Motor-A — today71.2%
CNC-3 — today88.4%
IATF 16949 Clause 8.5.1.1 requires OEE monitoring as part of manufacturing process control. Results feed directly into the PdM engine — a sustained OEE drop triggers a predictive maintenance alert.
6 big losses — Bogie Press 3 · This weekTPM analysis
1. Unplanned breakdowns
3.2h
2. Setup & changeovers
1.6h
3. Minor stoppages
1.3h
4. Reduced speed
2.0h
5. Process defects
0.6h
6. Reduced yield (startup)
0.4h
Unplanned breakdowns account for 45% of total loss time this week. The RCA engine has been triggered for the BP-3 HV fault (Job #1042). PdM interval has been reduced from 90 days to 60 days pending RCA closure.
Active permits
3
2 approved · 1 pending
Awaiting approval
1
PTW-004 — R. Adams
Closed today
2
Immutable · Hash verified
LOTO active
2
BP-3 · CNC-3
⚡
PTW-003 — High Voltage Work · Bogie Press 3
Raised: T. Nkosi · Asset: BP-3 · Valid: 09:00–17:00 today
1 Raised
2 Safety reviewed
3 Supervisor approved
4 LOTO confirmed
5 Work in progress
6 Close & reinstate
🔧
PTW-004 — General Maintenance · CNC-3 Bearing Replacement
Raised: R. Ndlovu · Asset: CNC-3 · Awaiting Plant Manager approval
1 Raised
2 Safety reviewed
3 Supervisor approval
4 LOTO
5 Work in progress
6 Close & reinstate
Once a permit is closed, it is permanently locked — is_immutable = TRUE is set and a SHA-256 hash is computed. No role — including Admin — can modify a closed permit. This satisfies ISO 45001 requirement for tamper-proof safety records.
Raise new permit — select type
⚡
High Voltage
HV systems >1000V
🕳
Confined Space
Gas testing required
🪜
Working at Heights
>2m above ground
🔥
Hot Work
Welding, grinding, cutting
🔧
General Maintenance
Standard mechanical work
Asset
Valid from
Valid until
Work description
LOTO required
RCA-009 — 5-Why analysis · HVAC Motor-A bearing failureIn progress
Asset: HVAC Motor-A · Failure date: 31 Mar 2026 · Job: #1041 · Analyst: T. Nkosi
1
Why did HVAC Motor-A fail?
The main spindle bearing seized, causing the motor to overheat and trip the thermal protection relay.
2
Why did the bearing seize?
The bearing was operating at 42kW — 12% above its rated load — for an extended period, causing accelerated grease degradation and metal fatigue.
3
Why was the motor operating above rated load?
The refrigerant charge had dropped 18% below specification, forcing the compressor to work harder to maintain setpoint temperature.
4
Why did the refrigerant level drop?
A slow leak developed at the condenser coil joint — the type NBR-70 seal is incompatible with the R-410A refrigerant at operating temperatures above 75°C.
5
Why was an incompatible seal specified?
✓ Root cause identified
The original equipment specification document (2019) did not include the revised R-410A operating temperature requirement. The procurement team sourced NBR-70 seals based on the outdated spec. No engineering change notice (ECN) was issued when the refrigerant was changed from R-22 to R-410A in 2021.
Fishbone diagram — 6M cause & effect · HVAC Motor-ARCA-009
HVAC Motor-A
Bearing Failure
Bearing Failure
Machine
Overloaded motor
Thermal relay aged
Material
Wrong seal spec
R-410A refrigerant
Method
No ECN issued
Outdated spec doc
Measurement
No load monitoring
Late leak detection
Man
Procurement gap
Training not updated
Environment
High ambient temp
Summer loading peak
Corrective actions — RCA-0093 open · 1 closed
| CA ref | Action | Owner | Due | Status | PdM link |
|---|---|---|---|---|---|
| CA-009-01 | Replace NBR-70 seals with EPDM-90 across all HVAC units — compatible with R-410A at 95°C | T. Nkosi | 07 Apr 2026 | In progress | PM updated |
| CA-009-02 | Issue ECN-2026-014: Update all equipment specs referencing R-22 to R-410A operating parameters | R. Adams | 14 Apr 2026 | Not started | — |
| CA-009-03 | Enable continuous motor load monitoring on SCADA for all HVAC units — alert at >95% rated load | K. Mokoena | 10 Apr 2026 | In progress | PdM threshold set |
| CA-009-04 | HVAC-A refrigerant recharge and leak test — return to full operating specification | T. Nkosi | 02 Apr 2026 | Complete | — |
CA-009-03 is linked to the PdM engine — the Weibull failure probability model for HVAC Motor-A has been updated with the new load threshold. The next scheduled PM interval has been reduced from 90 to 60 days. MTBF trend monitoring is active.