Free tools for production and field engineers

Efficiency and quality

• OEE calculator

  Availability, performance, quality and OEE step by step, with losses in minutes and the biggest one flagged.

  Guide: What is OEE?

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• MTBF and MTTR calculator

  Mean time between failures, mean time to repair and availability, compared with OEE availability.

  Guide: MTBF and MTTR explained

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• Downtime cost calculator

  The cost of one hour and one year of downtime from lost output, labour and other costs.

  Guide: Production tracking systems

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• Takt time and capacity calculator

  Takt time from demand and available time; bottleneck and required stations from station cycle times.

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• Cp and Cpk calculator

  Paste your measurements to get Cp, Cpk, Pp, Ppk, mean, standard deviation and a histogram with tolerance lines.

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Field communication and PLCs

• Modbus calculator

  CRC-16 and RTU frame builder, register address converter (40001 ↔ offset) and float/int decoder (ABCD, CDAB, BADC, DCBA).

  Guide: PLC data collection

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• 4–20 mA and analog scaling

  Converts 4–20 mA, 0–10 V and raw PLC counts (e.g. Siemens 0–27648) to engineering units and back.

  Guide: PLC data collection

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Energy

• Compressed air leak cost calculator

  Leak flow, annual kWh lost and cost from hole size, pressure and running hours.

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Assessment

• Digital maturity self-assessment

  Rates your plant's data collection, connectivity, monitoring, integration, analytics and organisation in 18 questions, with first steps.

  Guide: Digital transformation support in Turkey

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Excel templates

• Excel · .xlsx

  Production tracking and OEE form

  Shift and machine production log: work order, counts, downtime and scrap reasons from drop-down lists; OEE calculated on every row and per machine.

  Guide: Production tracking systems

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• Excel · .xlsx

  Failure log and MTBF / MTTR template

  One row per failure: start, reported, repair start and back-in-production times. Repair time, delays, MTBF, MTTR and availability calculated per machine.

  Guide: MTBF and MTTR explained

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• Excel · .xlsx

  Cp / Cpk template

  Paste measurements to get mean, standard deviation, short-term sigma from the moving range, Cp, Cpk, Pp and Ppk automatically.

  Guide: Cp and Cpk calculator

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• Excel · .xlsx

  PLC signal list template

  The list to fill in before collecting data from a PLC: signal, address, data type, scale, unit, read interval and verification at the machine.

  Guide: PLC data collection

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The templates and calculators are free. Use them in training, presentations or on your own site; a link back to this page is all we ask.