Frequent configuration changes were required to adapt to different product runs, with machines being relocated across lines or new machines being introduced. This lack of consistency made it nearly impossible to measure and monitor performance metrics effectively.

• Machine-Level Tracking: Deployed OEE on each machine’s controller to monitor running, starved, and blocked states in real-time.
• Line-Level Tracking: Configured performance tracking based on physical locations instead of individual assets. Ethernet and power infrastructure were standardized across all line positions, enabling seamless plug-and-play functionality as machines were moved or replaced.
• Unique Identifiers: Ensured each machine was tracked individually using hardcoded identifiers, providing clear and accurate performance data regardless of location.

• Real-Time Problem Identification: Operators could quickly identify and resolve issues, minimizing downtime.
• Performance Improvement: Production performance increased by 9% within the first three months of deployment.
• Shift Optimization: An average reduction of two shifts per week was achieved, lowering labor costs and improving efficiency.
• Targeted Training: Data insights enabled customized operator training to address specific pain points and enhance performance further.