Production monitoring and OEE tracking
Situation
The company had no real-time picture of production. Plan and actual output were compared only after the fact, which also held up dispatch planning.
Solution
A final line controller was integrated: for every product it provides the standard time of the whole line and a quality reading. Downtimes are entered by the operator on a handheld – planned ones (maintenance, cleaning) are evaluated against their own adherence KPIs, unplanned ones (equipment failure, missing material) are recorded separately. A collection unit right at the line evaluates the data continuously, and an ERP link compares it with the plan by product type.
How we read the numbers on this site: The figures in these studies come from people inside those operations – engineers and managers who dug the savings out of their own data. They are not audited or officially approved; companies do not publish numbers like these. That is why we do not name the customers, and why every figure says where it comes from.
Result
The performance and quality components come straight from the controller, and the operator-entered downtimes determine availability – together the full OEE, plus order fulfilment. On top of that, a prediction of output to the end of the shift, which production management works with directly. The measurements showed room to raise output per worker by roughly 20 %; standards were aligned with the actual measured times, and output per shift grew without hiring.
Honest numbers
We do not publish a financial figure for this deployment yet – we are verifying the underlying data with the customer. The measurable outcome is stated above. The platform price is not included in any calculation on this site.