Reference data · September 1, 2026
The numbers everyone quotes, sourced
Use these as calculator defaults and sanity checks. Vendor-reported figures are labeled — weigh them accordingly.
OEE benchmarks
| Metric | Benchmark | Source |
|---|---|---|
| World-class OEE (discrete) | ≈ 85% | Industry-standard benchmark |
| Typical measured plant | ≈ 60% | Industry-standard benchmark |
| Typical unmeasured line (first instrumentation) | 40–50% | Commonly observed at first automated measurement |
| Realistic ML-program gain | 3–10 OEE points | Deployment-reported range |
Downtime
| Metric | Benchmark | Source |
|---|---|---|
| Fortune Global 500 downtime loss | ~11% of revenues | Siemens, The True Cost of Downtime |
| Automotive downtime cost | > $2M per hour | Siemens, The True Cost of Downtime |
| Recovery from condition-based programs | 20–50% of unplanned stops | Practitioner-reported range |
| Group-scale PdM savings (public case) | ≈ €270M / year | Renault, 2024 (public) |
Scrap & quality
| Metric | Benchmark | Source |
|---|---|---|
| Typical scrap rate, discrete/process | 1–5% of units | Industry range |
| Typical ML root-cause reduction | 10–30% | Deployment-reported range |
| Best published reduction | −58% | JEMBA (vendor-reported) |
| Leading AI use case (inspection) share | ≈ 11% of industrial AI use cases | IoT Analytics |
Energy
| Metric | Benchmark | Source |
|---|---|---|
| Program-style savings (ISO 50001 approach) | 5–15% | Industry range |
| ML setpoint/sequence optimization | up to −20% | JEMBA (vendor-reported) |
| Typical EU industrial tariff (2026, blended) | 100–200 €/MWh | Market range |
Keep them handyThe ROI workbook ships these benchmarks beside the calculators, in one sheet.
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All four loss calculators — downtime, OEE, scrap, energy — in one Excel sheet, with conservative / typical / best-published scenario columns. Built for your budget meeting.
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