Free manufacturing tools
Calculators for OEE, capacity, line pace, quality and maintenance, plus templates and reference pages. Each one gives a result as you type, with no signup.
Start here
Three places most plants start: the OEE calculator for a one-off number, the free CMMS app for work orders and PM plans, and the free OEE tracker when you want the number every shift. None of them needs an account, and every calculator below shows its result as soon as you type.
OEE Calculator
Enter planned time, downtime, ideal cycle time and good and total counts, and get Availability, Performance, Quality and OEE with the formula shown.
Free CMMS App
Work orders, PM plans with checklists, a maintenance calendar, machines with QR labels and an OEE shift log, in the browser with no account. Data stays on this device.
Free OEE Tracker
Log a shift by hand and see OEE, the Availability, Performance and Quality split, a downtime Pareto and a benchmark, then raise work orders and PM reminders. Data stays in your browser.
OEE and capacity
Measure how well equipment turns scheduled time into good output, what the gap is worth, and where a plant loses the most.
Availability Calculator
Enter scheduled time, planned stops, breakdowns, other stops and changeovers, and get availability, what counting planned stops would change, inherent availability, MTBF and MTTR.
TEEP Calculator
TEEP multiplies OEE by utilization, so it shows how much of the calendar your equipment turns into good output, including the hours you never schedule.
Six Big Losses Calculator
Enter the minutes lost to breakdowns, setups, small stops, slow cycles and rejects, and see your OEE, its split and which loss is the largest.
Hidden Factory Calculator
Estimate what short stops and reduced speed cost in units, money and OEE points when they never reach the downtime log.
Production Capacity Calculator
From run rate, shifts and OEE, see theoretical capacity, the output you can actually promise and the capacity lost to downtime.
Factory Loss Scan
Answer a short set of questions about your plant and get an estimate of the yearly loss you could recover, and where the biggest share sits.
Line pace, changeovers and quality
Set the pace a line must hold, balance its stations, price the time lost to setups, and see how much output scrap and rework take away.
Cycle Time Calculator
Cycle time is net production time divided by units produced. Get the real time per unit, throughput per hour and per shift, and compare it with takt.
Takt Time Calculator
Takt time is available production time divided by customer demand. See the pace the line must hold and whether your cycle time keeps up.
Line Balancing Calculator
Enter station times and takt, and get balance efficiency, balance delay, the theoretical minimum number of stations and the bottleneck.
Changeover Cost Calculator
Enter current and target changeover times and frequency, and see the hours, good units and money per year a faster setup returns.
Scrap Rate Calculator
From produced, scrapped and reworked units and their cost, get scrap rate, first pass yield and the yearly cost of poor quality on the line.
First Pass Yield Calculator
Enter each process step's yield and see first pass yield per step and the rolled throughput yield of the whole line.
Maintenance and reliability
Size failures, backlog, spare parts and maintenance spend, see what downtime costs, track the maintenance KPIs month by month, and look up why a machine fails.
MTBF and MTTR Calculator
From operating time, number of failures and repair time, get MTBF, MTTR, failure rate and inherent availability.
Maintenance Backlog Calculator
Enter outstanding work hours and crew capacity and see your backlog in weeks of work, with the range the page uses as healthy.
Maintenance Cost as % of RAV
Enter yearly maintenance spend and replacement asset value and see the ratio, the usual way to compare maintenance cost between plants.
Preventive Maintenance ROI Calculator
Compare running an asset to failure with a preventive maintenance program and see the net yearly saving and the return on planned work.
Spare Parts Inventory Cost Calculator
Add the carrying cost of the spares you hold to the downtime cost of the critical parts you run out of, and see what the storeroom costs per year.
Downtime Cost Calculator
Turn downtime hours into a yearly figure from lost throughput, idle labor, scrap and restart, with the cost of one hour.
CMMS ROI Calculator
Model the payback and yearly net saving of a CMMS against your current downtime losses.
Maintenance KPI Tracker Template
Enter a month of maintenance numbers and track MTBF, MTTR, availability, PM compliance, planned maintenance, backlog and cost against RAV over 12 months.
Troubleshooting Directory
Search 2660 documented problems across 309 equipment types, each with likely causes and the fix, or describe a symptom in the symptom finder.
Templates
Sheets you fill in the browser, print or download for Excel. See all templates for how they fit together and which one to start with.
Downtime Log Template
Record every stop by machine, reason and duration in the browser and see a Pareto of the biggest causes, or download the Excel log with its Pareto chart and the PDF to fill by hand.
OEE Tracking Template
Log downtime, output and quality per shift and get Availability, Performance, Quality and OEE worked out, or download the Excel workbook with a weekly trend and the six big losses, and a PDF shift sheet.
Preventive Maintenance Checklist Template
Checklists for 10 machine types, daily to annual. Edit them in the browser, or download the free Excel, PDF and Word files.
Maintenance Work Order Template
Fill in a work order for a machine in the browser and print it, or download the Excel version with a work order log, the Word form or the PDF.
CMMS Excel Template
A free CMMS in Excel: a machine list that imports into the free app, a PM schedule with due dates, a work order log, parts and KPI formulas.
Autonomous Maintenance Checklist
Daily and weekly operator checks by machine type: clean, inspect, lubricate and tighten, with initials, time and OK or problem, and a red tag log.
Reference and data
Open data the calculators link to: OEE by industry, how much of its capacity each industry uses, and what maintenance mechanics earn by state.
OEE and Downtime Benchmark
OEE, downtime and short stop ranges by manufacturing industry, aggregated from public studies, with the sources listed on the page.
Capacity Utilization by Industry (Census)
How much of their full production capacity US plants used, for 90 industry groups over the last 8 quarters, with a CSV.
Maintenance Mechanic Pay by State (BLS data)
Pay and employment of industrial machinery mechanics and maintenance workers in every state, for loaded labor rates in your cost math.
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