Manufacturing OEE Dashboard
Client
Netherlands Manufacturing Co.
Technologies Used
The Challenge
A mid-size manufacturing company had 15 production lines generating data, but no way to see real-time performance. Downtime was reactive, not proactive. Management had no visibility into bottlenecks.
Key problems:
- - No real-time machine status
- - Downtime not tracked systematically
- - Quality issues discovered too late
- - No way to compare line performance
The Solution
Integrated all 15 PLC systems using OPC UA and MQTT protocols. Built an edge data collector to aggregate and filter data locally. Created a cloud-based time-series database (InfluxDB) to store historical data.
Developed a real-time OEE dashboard showing:
- - Live machine status (running/idle/error)
- - Production counts vs. targets
- - Downtime events with categorization
- - Quality metrics and defect rates
- - Line-by-line comparison
- - Trend analysis over time
Implemented alerting system for:
- - Machine downtime > 5 minutes
- - Quality deviations
- - Production target misses
The Results
Implementation completed in 12 weeks.
18% reduction in unplanned downtime
12% increase in overall throughput
25% faster response to quality issues
Management now has real-time visibility
ROI achieved in 8 months
Client quote: "We can finally see what's happening on the floor in real-time. Game changer."