Production & OEE Reporting
Availability, quality and performance as a metric instead of gut feeling.
We build OEE reporting that combines machine data from MES systems with scrap and downtime data. Plant managers and shift leads see bottlenecks and quality issues before they turn into outages.
- Transparency on actual machine utilization.
- Faster detection of quality problems.
- Comparability between lines and plants.
OEE improvement in pilot plant
unplanned downtime
instead of weekly evaluation
faster root-cause analysis
Calculated from additional production time from less downtime versus project cost.
- 01
Machine assessment
We check which machines already deliver data and where sensors are missing.
- 02
Define OEE
Availability, performance and quality are defined consistently plant-wide.
- 03
MES connection
Machine and downtime data are connected from the MES.
- 04
Shopfloor dashboards
Shift leads get dashboards directly at the line.
- 05
Continuous improvement
OEE data feeds into the continuous improvement process.
Steps
Data sources
Stakeholders
From first data access to production – every step delivers a tangible interim result.
Machine data
Cycle, runtime and fault data from the MES system.
Quality data
Scrap and rework rates from the quality system.
Order data
Manufacturing orders and target quantities from the ERP.
Shift plans
Staffing and shift plans to attribute downtime.
Maintenance data
Maintenance plans and fault reports from the maintenance system.
Sensor data
Temperature, pressure or vibration readings from individual machines.
Plant management
Compares lines and plants using consistent OEE figures.
Shift leads
Reacts directly at the line to identified bottlenecks.
Maintenance
Prioritizes maintenance based on actual fault frequency.
Executive management
Sees productivity development across plants.
Transparency on actual machine utilization.
Faster detection of quality problems.
Comparability between lines and plants.
Better basis for investment decisions.
Fewer manual shift logs and Excel lists.
With a solid data foundation this use case gets faster, cheaper and far more stable.
Unified data models make plants and lines comparable.
Real-time MES connectivity delivers current metrics.
Historized data enables trend and root-cause analysis.
A scalable architecture allows rollout to further plants.
Management cockpit
OEE metrics become visible across plants in the management cockpit.
Supply-chain reporting
Production data improves delivery-reliability forecasts in the supply chain.
Predictive maintenance
The same machine data serves as a basis for predictive maintenance.
Management Cockpits
Revenue, margin and cash at a glance – updated daily instead of once a month.
Finance & Controlling Reporting
Month-end close and cost-center reports without an Excel marathon at the start of the month.
Sales & CRM Analytics
Make pipeline, forecast and customer potential visible instead of guessing in the CRM.