All case studies
An OEE baseline for a floor with no machine data
Electronics contract manufacturer, Penang · 3 lines · 48 machines · 7 months
Measured outcomes
- +9.6 pts
- OEE improvement
- -24%
- Unplanned downtime
- 100%
- Machines instrumented
- 5 min
- Shift report lead time
Starting point
Downtime was recorded on whiteboards and re-keyed into spreadsheets the next morning. Two of three lines had no controller access, and OEE numbers differed between production and finance.
“For the first time the morning meeting starts from data everyone trusts.”
What we deployed
- Current-clamp and vibration sensing for machines without PLC access
- OPC UA and Modbus gateways where controllers were available
- Operator tablets for two-tap downtime reason capture
- Edge buffering so the line keeps recording through network loss
What changed
- One agreed OEE definition shared by production, quality and finance
- Top five downtime reasons ranked weekly and worked as a queue
- Retrofit approach reused on a second plant without vendor lock-in
Client names are withheld under commercial confidentiality; figures are drawn from post-deployment reviews agreed with each client.
