Production Tracking
Challenge
The Problem
Production reporting was done manually at end-of-shift on paper forms. Managers discovered quality issues and material variances hours after they occurred. OEE was unknown — estimated at 52% based on anecdotal observations.
Approach
Our Solution
We integrated with existing PLCs via OPC-UA, capturing machine states in real time. An MES layer tracks work orders from raw material intake to palletized output. Automated shift reports replace manual paperwork, and a live OEE dashboard is visible on shop-floor screens and managers' phones.
Outcomes
Results Achieved
↑ 23% OEE improvement (52% → 64%) in 6 months
Shift reports automated — from 45 minutes to zero manual effort
Material variance visibility reduced loss by 8%
Real-time production data for all 6 production lines
Business Impact
ROI Statement
OEE improvement equivalent to adding 0.7 production lines without capital investment. Annual throughput gain valued at ~$560,000.
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