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Is a Changeover Planned Downtime or an Availability Loss? — How the Definition Changes OEE
Whether a changeover (also called a setup) counts as planned downtime or as an availability loss differs from source to source, and because that choice alone changes availability and OEE substantially, changeover time must be tracked as a metric separate from OEE. The "Downtime" entry in the Lean Enterprise Institute (LEI) lexicon classifies changeovers to produce other products as planned downtime, while the Japan Institute of Plant Maintenance (JIPM) classifies setup and adjustment as a stop loss in availability. In an assumed shift (loading time 27,600 s, changeovers 3,000 s, breakdowns 600 s), availability is 87.0 % under the JIPM approach and 97.6 % under a planned-downtime approach that subtracts…
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Line Changeover Design in the Era of Low-Price ESS Round-3 Bidding — Flexible Assembly Viewed Through Takt Time and OEE
Korea's ESS centralized-contract market Round-3 bid (approximately KRW 1 trillion), scheduled for announcement in September 2026, has already shown a decline in bid prices compared to Rounds 1 and 2, intensifying low-price order competition among the three battery makers. This article focuses on the possibility that this low-price order volume will require cell-format mixed-model flow on an existing single-model production line, and quantifies, as a target scenario, the impact of changeover time on takt time and the OEE Availability factor. The verification shows that controlling changeover time within the 216 s target versus exceeding it by 50% produces an OEE gap of approximately 3.8 pp. However, these figures are an…
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