Actual Run Rate

Actual run rate refers to the real-time measurement of output achieved by a piece of equipment in a manufacturing process. 

This metric shows how much product is produced compared to the maximum output the equipment can achieve.

Actual run rate is calculated by considering the time the equipment is operational and the rate at which the product is produced. 

You can express this as the number of units produced per hour. 

This figure allows for direct comparisons between expected and actual productivity. 

Monitoring the actual run rate helps identify inconsistencies in performance that affect the overall efficiency of manufacturing.

Actual Run Rate and OEE

The actual run rate plays a critical role in Overall Equipment Effectiveness (OEE). 

High actual run rates contribute positively to OEE scores, indicating effective equipment usage. 

When actual run rates fall below expected levels, OEE decreases, signalling potential issues like equipment downtime or inefficiencies in production processes. 

Improving actual run rate directly enhances OEE and leads to better manufacturing outcomes.

 

How to Calculate Actual Run Rate

The formula for calculating actual run rate is straightforward. Use the following equation:

Actual Run Rate = Total Units Produced / Production Time (hours)

For example, if a machine produces 500 units in 8 hours, the calculation appears as follows:

Actual Run Rate = 500/8 

(62.5 units per hour) 

This calculation provides a clear indication of performance within your manufacturing process. 

Ensure data accuracy to obtain reliable results that contribute to assessing overall equipment effectiveness.

 

What influences Actual Run Rate?

Equipment Speed

The speed at which equipment operates determines the maximum potential output within a given timeframe. 

Variations in speed can result from settings adjustments, mechanical limitations, or wear and tear. 

If equipment operates below its designed capacity, the actual run rate decreases, directly lowering OEE.

Downtime (Planned and Unplanned)

Both planned and unplanned downtime significantly impact actual run rates. 

Planned downtime, such as for cleaning or tool changes, temporarily halts production but is accounted for in schedules. 

Unplanned downtime due to equipment failure or system errors disrupts operations unpredictably, causing more severe drops in run rate and creating bottlenecks in production.

Maintenance Schedules

Effective preventive maintenance ensures that equipment remains in optimal condition, reducing the likelihood of unplanned downtime. 

Reactive or delayed maintenance, however, can lead to reduced equipment efficiency, slower operation, and unplanned repairs that disrupt production flow, thereby negatively impacting the actual run rate.

Operator Efficiency

The proficiency and experience of operators directly affect how efficiently equipment is utilised. 

Skilled operators can quickly respond to issues, perform setups efficiently, and maintain consistent operation speeds. 

Inadequate training, fatigue, or operator error can lead to slower processes, setup delays, or even equipment damage, all of which lower the actual run rate.

Material Quality

High-quality raw materials facilitate smoother operations and reduce setup times. 

Poor material quality, however, may require additional adjustments or cause jams, defects, or rework, all of which delay production. 

Inconsistent material quality can also force operators to slow down equipment to maintain quality standards, further lowering the run rate.

Together, these factors highlight the interconnected nature of production processes and their influence on the Actual Run Rate in OEE.

 

Why Measure Actual Run Rate?

Improved Production Efficiency

Improved production efficiency results from identifying gaps between expected and actual performance. 

Knowing the actual run rate allows you to pinpoint exact inefficiencies. 

You can target areas such as equipment performance or operator productivity for enhancements.

Streamlining these elements maximises output, which positively affects overall equipment effectiveness (OEE) metrics.

Better Decision-Making

When you monitor actual run rates consistently, you gain a clearer picture of manufacturing capabilities. 

This data informs strategic decisions about equipment upgrades or maintenance schedules. 

With accurate information at your disposal, you can respond proactively to issues that may impede production, ensuring that you maintain optimal operational efficiency.

Our Expert team are here to help…

We’d love to talk to you about POET.

Let’s Talk OEE

See how POET can benefit your business

    Please prove you are human by selecting the house.

    Explore other terms