Project background
A manufacturer running several lines needed unified visibility into production — OEE, downtime causes, quality trends — instead of the current mix of operator whiteboards and periodic reports.
Challenge
Pulling data from varied PLCs without disrupting production, defining consistent OEE calculations across different line architectures, and presenting the result to operators, supervisors, and plant management with views each one actually wanted.
Approach & solution
We deployed edge gateways that bridge OPC UA and Modbus to a common schema, then built a tiered dashboard for operators, supervisors, and management. Downtime auto-categorizes based on PLC signals, with operator overrides for nuance. Historical comparisons help identify chronic issues.
Results & benefits
OEE visibility became real-time instead of next-day, and chronic downtime issues that had hidden in aggregates became visible and addressable. Plant management now runs weekly reviews off the dashboard directly.
