OKThe time the line is stopped
Breakdowns, format changes, waiting for material. We know when, how long and why.
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Production data · OEE
OEE, downtime and waste: find out where your output goes
Almost every line produces less than it could, and the cause is seldom known with certainty. We measure how much your line produces, how long it stands still and how much product is discarded, and we present it in a report you can read in five minutes.
What we do
From the PLC to the weekly report
We connect to the line's PLC and to the systems you already have, collect running time, stops and rejects, and turn them into figures anyone can understand: how much was made, how much was discarded and how long the line was stopped, and why.
- OEE per line, per shift, per day and per week
- Every stop with its duration and its reason
- Waste and rejects counted, not estimated
- Instant alerts by email, Telegram or WhatsApp
- The full history, downloadable as CSV
What OEE is
One figure, three losses
OEE (overall equipment effectiveness) sums up in one percentage how much of what your line could produce actually comes out good. Behind it are three different losses, and each one is tackled differently.
The line runs, but below its speed
Micro-stops and speed below nominal: the loss that is hardest to see.
What is produced and discarded
Rejects and waste counted at every point of the line, so you know where they start.
New · OEE per machine
The machine to blame for every stop
Line OEE tells you how much you lose; machine OEE tells you where. With photocells between machines we know which one stopped by itself and which were only starved or blocked, and every morning the efficiency-killers report arrives: the Pareto of line minutes lost per machine, micro-stops versus stops, an hourly map and the packs lost.
- The machine that costs you the most line minutes, named
- Micro-stops (10 s to 2 min) and stops (2 min or more), kept apart
- OEE waterfall according to ISO 22400-2
- AI commentary with the next step
Why did line 2's OEE drop on Tuesday?
OEE by day · line 2 · %
On Tuesday line 2 was stopped for 1 h 52 min: 1 h 10 min for a format changeover that overran and 42 min of micro-stops at the labeller. Without that changeover, OEE would have been 77%.
Source: line 2 stops on Tuesday and the changeover log
Mock-up with demo data.
How we start
Measure first, improve next
- Visit: which line worries you and what data it already produces.
- Connection: I/O, Modbus TCP, OPC UA, SQL or CSV, depending on your plant.
- First figures: real OEE, downtime and waste from your shifts.
- AI analysis: a virtual analyst sums up the week and points to where the margin is.
- Continuous improvement: we tackle the costliest loss first and measure the result. Continuous improvement →
FAQ
Answers to the most common questions
What is a good OEE for a packaging line?
There is no single figure that suits every line: it depends on the product, the format and how many changeovers you make each day. What helps is measuring your line with the same rule, shift after shift, seeing which of the three losses costs you most and checking that it goes down week after week. That is why we measure first, before promising any target.
What is OEE and how is it calculated?
It is overall equipment effectiveness: it multiplies availability (running time), performance (actual speed versus nominal speed) and quality (good product versus total). An OEE of 100% would mean always running, at full speed, without discarding anything.
Do I need to change my machines or my PLC?
No. We connect to what you already have and, if a signal is missing, we add only the minimum needed.
Where does my data stay?
The data is yours and stays in your plant. The cloud only receives what you decide.
Can we start with a single line?
Yes, and that is what we recommend: start with the line that worries you most, measure it and expand from there.
What does an OEE of 85% mean?
That, of everything the line could produce in the planned time, 85% comes out as good product; the rest is lost to stops, running below rated speed or scrapped product. 85% is often quoted as a world-class benchmark, but what matters is comparing your line with itself: knowing which of the three losses weighs most and bringing it down.
How do you calculate OEE in Excel?
With three columns per shift: availability (run time ÷ planned time), performance (units produced × ideal cycle time ÷ run time) and quality (good units ÷ units produced). OEE is the product of the three. The weak point of a spreadsheet is that it depends on someone logging stops by hand; our OEE demo shows what it looks like when it is measured automatically.
Let's talk about your plant
Do you know how much your line actually produces?
Tell us which line worries you. We will suggest how to measure it and where to start improving.