OEEPerformance & Intelligence
Overall Equipment Effectiveness
Maximize Efficiency with Real-time Monitoring & Analytics Real-time monitoring and analytics of equipment effectiveness that help eliminate the Six Big Losses and unlock the hidden factory.
The challenge
Manufacturing operations typically run at 40-60% Overall Equipment Effectiveness (OEE), well below the world-class benchmark of 85%, and every percentage point of improvement directly affects profitability. While OEE remains a monthly Excel calculation, production losses and the unused capacity of the hidden factory stay out of sight.
Overview
The LOGICAL SYSTEMS OEE application gives operations teams real-time visibility into equipment effectiveness. Built on the Inductive Automation Ignition platform, it automatically calculates and tracks key performance indicators and connects to existing automation infrastructure through standard protocols including OPC, MQTT and Modbus, with no disruption to current operations. Dashboards show equipment status, production rates and quality metrics, while analytics help continuous improvement teams systematically eliminate the Six Big Losses.
Production counts, equipment states and quality results are collected automatically from sensors, PLCs, barcode scanners, automation signals and inspection systems, with configurable thresholds to detect micro-stops. The application exchanges data with ERP, CMMS and LIMS, models unlimited equipment hierarchy levels and classifies downtime with configurable reason trees. Mobile-responsive interfaces and role-based access control get the right information to the right people, and the application scales from a single production line to a global manufacturing network.
Typical results
Typical results reported in the OEE datasheet. Results depend on each site's starting point and scope.
Capabilities
What OEE does
From Intuitive Configuration to Dashboards with Real-Time Insight
- Live equipment status cards with real-time OEE and colour-coded indicators
- Production KPIs: overall OEE, equipment status counts, active alerts and shift progress
- Per-equipment OEE with availability, performance and quality breakdowns
- Per-equipment mini trend charts showing performance over time
- Production details: current product, order progress, target speeds and counts
The Six Big Losses Framework
- Availability losses: equipment failures, and setup and adjustments
- Performance losses: idling and minor stops under 5 minutes, and reduced speed
- Quality losses: process defects, and reduced yield during start-up or fine-tuning
Comprehensive Data Collection and Integration
- Production counts from sensors, PLCs and barcode scanners
- Running, idle and down states captured directly from automation signals
- Speed and rate monitoring against ideal cycle times, with micro-stop detection
- ERP: schedules and work orders in; actual production and efficiency metrics out
- CMMS: automatic work orders for failures; MTBF and MTTR tracked alongside OEE
- LIMS and quality systems: inspection results in; quality alerts and defect tracking out
Key Features
- Automatic OEE calculation from real-time equipment data
- Configurable downtime reason trees with operator validation
- Multi-level equipment hierarchy and configuration tools for equipment, products and schedules
- Shift-based tracking, historical trending and automated threshold notifications
- Event management with timeline visualisation and a low-code logic engine
- RBAC with site-level restrictions, theme management, quick export and CI/CD-ready deployment
Benefits
Why manufacturers choose OEE
More production, same assets
A 10% OEE improvement means 10% more production from existing assets, by uncovering unused capacity in the hidden factory.
Less unplanned downtime
Real-time monitoring and alerts enable immediate response to equipment issues, reducing downtime that disrupts production schedules.
Lower quality costs
Tracking quality metrics at the source improves first pass yield and reduces scrap and rework.
Lower overtime and maintenance costs
Better equipment utilisation reduces overtime costs, and proactive intervention decreases maintenance costs.
Improved on-time delivery
Capacity planning based on demonstrated equipment capability, not theoretical capacity, improves on-time delivery.
ROI within six months
Typical ROI within 6 months through downtime reduction (20-30%), speed recovery (10-15%) and quality improvement (5-10%).
OEE gave us the data we needed to make better decisions. No more guessing why our lines weren't hitting targets.
Ask OEE in plain language
LS Assistant, the AI assistant in every Logical Systems application, answers questions from your live OEE records and shows the sources behind every answer. It keeps learning as your records, work instructions and resolved issues grow, and your data is never used to train AI models.
Answers with sources
Every answer cites the records and work instructions it used.
Your role, your site
It sees only what each user is allowed to see.
Asks before it acts
Every change it proposes needs a person's confirmation and is audited.
18 languages, voice on mobile
Questions, answers and content in your teams' languages.
Integration
Connects to the systems you run
Systems & protocols
- ERP
- CMMS
- LIMS
- quality inspection systems
- PLCs
- sensors
- barcode scanners
- Modbus
- MQTT
- OPC UA
- OPC DA
- REST API (JSON payloads)
- Kafka (via connector)
- Snowflake (via pipeline, data bridge)
Works with
Related solutions
See OEE in action
Book a demo with our engineers, using scenarios from your own plant.