Real-Time Machine OEE Monitoring System
Track Availability. Measure Performance. Optimize Quality. Boost Asset Utilization.
If you don't measure machine effectiveness, you cannot optimize it. Relying on operators' manual shift-end reports introduces lag, inaccuracies, and missed optimization chances. Our Real-Time Machine OEE Monitoring System captures live machine states directly from the shop floor, giving you instant visibility into Availability, Performance, and Quality parameters.
Powered by non-invasive IoT retrofits and advanced PLC polling protocols, our system converts machine data into visual, actionable supervisor dashboards.
Unified OEE Metrics Tracking
Automatically calculate and track the three pillars of Overall Equipment Effectiveness:
- Availability (Uptime): Live tracking of running vs downtime states, capturing micro-stops instantly.
- Performance (Speed): Compares actual cycle speeds against standard theoretical rates to capture slow cycles.
- Quality (Defects): Cross-references finished items with reject logs to map net yield.
Smart IoT and Machine Interfacing
Bring the digital thread to legacy and modern equipment alike:
- Connects directly to modern CNC, injection molding, and packaging PLCs via OPC-UA, Modbus, and EtherNet/IP.
- Retrofits older machines with non-invasive sensors (CT sensors, proxy sensors, smart relays) to track cycles.
- Shop-floor terminals allow operators to log downtime classifications (changeovers, cleanings, maintenance) instantly.
Actionable Predictive Maintenance and Alerting
Shift from reactive firefighting to predictive asset management:
- Logs cumulative machine cycles and prompts automated warnings before standard wear-out limits are hit.
- Supervisors receive instant notifications if machine speed or temperature deviates from tolerance boundaries.
- Enables clear Pareto charts pinpointing major downtime culprits for continuous improvement audits.
IoT Connectivity
Non-invasive gateways stream cycle telemetry directly from PLCs and proxy sensors.
Live Dashboard
Real-time shop-floor display of Availability, Performance, and Quality metrics per shift.
Micro-Stop Logging
Captures small, recurring 2-minute halts that add up to major capacity leakage.
Job Card Sync
Directly links machine cycles against active ERP production orders for accurate costing.
Why Implement Our OEE System?
- Increase overall plant OEE by 15% to 25% within the first six months.
- Uncover hidden capacity without purchasing new hardware assets.
- Eliminate manual shop-floor logs and error-prone paperwork.
- Track exact changeover times and establish standard setup routines.
- Extend machine life through structured preventive maintenance.
OEE System Overview
"FixonPro's OEE system exposed massive micro-stop issues in our injection molding section that manual logs completely missed. We optimized tool setup routines and recovered 22% capacity in just four months."
Optimize Your Plant Capacity
Learn how non-invasive IoT retrofits can reveal your machines' true utilization rates.
Frequently Asked Questions
Understand how IoT sensor data translates to actual capacity optimization.
What is OEE and how does FixonPro monitor it in real-time?
OEE stands for Overall Equipment Effectiveness, calculated based on Availability, Performance, and Quality. Our system connects directly to shop-floor machinery using IoT gateways and PLCs to monitor uptime, speed loss, and defects instantly without manual logging.
Can we monitor legacy machinery that lacks network capabilities?
Yes. We interface with legacy machines using non-invasive IoT retrofits (such as optical sensors, CT clamps, or micro-relays) to extract cycle counts and operating states securely.
How does the system identify the reasons for machine downtime?
When a machine stops, the system registers the halt immediately. Operators can classify the downtime reason (e.g., breakdown, setup change, material shortage) directly on terminal touchscreens situated at the machine workstation.
Does the OEE system synchronize with our ERP?
Yes, our OEE platform integrates bidirectionally with Fixon ERP and Odoo, updating job card progress, scheduling routines, and material consumption records instantly.
Are there real-time warning notifications for drop in production rates?
Yes, the system constantly tracks active speed rates. If a machine's performance falls below 80% of its standard cycle time, automated alerts are sent to supervisors via SMS, WhatsApp, and supervisor consoles.