Real-Time Productivity Monitoring with OEE (Overall Equipment Effectiveness)

Unlock the potential of your factory by optimizing asset utilization and tracking performance with real-time OEE.

Tracking Real-time Equipment Effectiveness with IndustryApps

The business wanted a new data-driven approach to track real-time performance changes and overall equipment efficiencies. They sought a solution that could collect and analyze data from diverse machines, enhance cybersecurity, and empower their internal teams to effectively manage and leverage the data.

Key Issues
  • Real-time data collection across heterogeneous machines.
  • Limited support from machine manufacturers.
  • Growing cybersecurity risks.
  • Lack of internal IT expertise for managing data security, storage, and analytics.
  • Comprehensive change management and training requirements.
Challenges

An Automotive Tier 1 supplier faced difficulties optimizing asset utilization due to a lack of transparent data on machine performance. As production volumes grew, the need for additional capacity became critical, but without insights into existing asset usage, planning for new investments was impossible. The factory, equipped with a mix of legacy and modern machines, faced these challenges:

Solution

IndustryApps delivered a turnkey solution that transformed the factory into a smart, connected operation. Key steps included:

Impact

Within 8 months, the factory transitioned from manual processes to a fully connected ecosystem:

  • All critical assets streamed real-time data to the cloud, offering complete transparency on utilization and downtime.
  • The solution enabled insights at the plant, production line, and asset levels.
  • The customer achieved an 18% improvement in OEE, avoiding significant capital expenditure on new machinery.
  • Flexibility increased to adapt to dynamic market conditions, resulting in an extension of the solution to three additional factories in just two months.

Key Deliverables

  • Private Smart Factory Instance: Built on Microsoft Azure with a RAMI 4.0 architecture.
  • AAS Standards: Centralized data for plants, machines, lines, and assets.
  • Real-Time Machine Connectivity: Continuous streaming every second.
  • IIoT Gateway Deployment: Seamlessly integrated with legacy and modern machines.
  • OEE Application Enablement: Comprehensive monitoring and analytics.
  • Downtime Reporting: Pareto charts and actionable insights.
  • Alerts and Notifications: Proactive measures for maintenance and downtime reduction.
  • Team Training: Empowering the local workforce to configure additional assets independently.

Ready to Revolutionise Your Industrial Operations?

Join the future of industrial digital transformation with IndustryApps. Experience seamless integration, unparalleled data control, and cutting-edge technology tailored to your needs.

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2.5M+

Digital Twins per Month

98.29%

Customer Satisfaction Rate

1M+

Streaming Machine Data Tags

Frequently Asked Questions

What is industrial data management, and why is it important?

Industrial data management involves collecting, integrating, and analysing data from various sources within an industrial environment. It is crucial for enhancing operational efficiency, making informed decisions, and driving innovation through real-time insights and predictive analytics.

Industrial data management involves collecting, integrating, and analysing data from various sources within an industrial environment. It is crucial for enhancing operational efficiency, making informed decisions, and driving innovation through real-time insights and predictive analytics.

How does an AI co-pilot improve industrial operations?

An AI co-pilot provides real-time insights and recommendations, helping operators optimize processes, reduce downtime, and improve productivity by leveraging advanced analytics and machine learning algorithms.

An AI co-pilot provides real-time insights and recommendations, helping operators optimize processes, reduce downtime, and improve productivity by leveraging advanced analytics and machine learning algorithms.

What’s the difference between cloud and on-premise solutions?

Cloud solutions are hosted online, offering flexibility and remote access. On-premise solutions are installed locally on your hardware, providing greater control and security.

 Cloud solutions are hosted online, offering flexibility and remote access. On-premise solutions are installed locally on your hardware, providing greater control and security.

How secure is your industrial automation software?

Our software includes robust security measures such as data encryption, regular updates, and compliance with industry standards to protect your data.

 Our software includes robust security measures such as data encryption, regular updates, and compliance with industry standards to protect your data.

Can your software integrate with my current systems?

Yes, our solutions are designed for seamless integration with ERP, MES, IIOT, and other IT systems, ensuring smooth operation across all platforms.

 Yes, our solutions are designed for seamless integration with ERP, MES, IIOT, and other IT systems, ensuring smooth operation across all platforms.

How long does it take to implement your solutions?

Implementation times vary based on the project’s complexity, but our streamlined process ensures you’re up and running quickly, minimizing downtime and disruption.

 Implementation times vary based on the project’s complexity, but our streamlined process ensures you’re up and running quickly, minimizing downtime and disruption.

What benefits does AI-supported data mapping provide?

AI-supported data mapping ensures consistency and accuracy across all data sources, enhancing data quality and facilitating advanced analytics and AI applications.

AI-supported data mapping ensures consistency and accuracy across all data sources, enhancing data quality and facilitating advanced analytics and AI applications.

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