OEE Monitoring and Production Analytics System for a Leading US-Based Manufacturer
Overview
The client needed a modern, real-time production monitoring solution to improve machine utilization, track OEE, and gain actionable insights while replacing their legacy system to enhance operational efficiency and meet production targets effectively
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Challenges
Lack of real-time machine data collection and visibility
Inability to automate OEE calculations across production levels
Manual downtime tracking causing delays and errors
Solution
- Installed data acquisition devices for real-time machine data collection
- Automated OEE calculation at machine, cell, and plant levels
- Deployed Smart Measuring Views near machines to display live production metrics
- Enabled operators to log downtime reasons for accurate analysis
- Integrated shift-wise production planning for performance tracking
- Provided downloadable report formats for OEE, Cycle Time, and Downtime KPIs
- Configured multi-level dashboards for real-time insights and centralized KPI monitoring
Outcomes
- Saved 25+ hours/month by automating production report generation
- Enabled real-time OEE monitoring and remote plant performance tracking for faster decision-making
- Improved production visibility with accurate cycle time, downtime reasons, and production count data
