Efficiency achieved through new methods using OEE indicators

The manufacturing industry is constantly evolving, and the fourth industrial revolution has brought a wave of technological changes that are completely transforming the way factories operate. In this context, productivity and efficiency have become the keys to standing out and succeeding in such a competitive market.

One of the most used metrics to measure productivity in a manufacturing line is the OEE (Overall Equipment Effectiveness). This indicator allows you to evaluate the performance of a machine, line, or entire plant in terms of availability, performance, and quality.

However, calculating and improving OEE is not a simple task. It requires the collection and analysis of a large amount of data in real time, as well as a thorough understanding of the factory's production processes and machines.

Allie's software simplifies this process by automating the collection and analysis of production data in real time, allowing you to obtain accurate and updated OEE metrics. In addition, our solution offers a series of additional tools and functionalities that allow you to identify improvement opportunities and optimize the productivity of your operation.

OEE is calculated by multiplying three factors:

Availability: ratio of actual operating time to planned operating time.

Performance: ratio of actual production rate to maximum theoretical rate.

Quality: ratio of acceptable units produced to total units produced.

The result of these three factors is expressed as a percentage. An OEE of 100% indicates that the line is operating at maximum capacity, with no downtime, at maximum speed, and producing only quality units.

An OEE of 85% or higher is considered world-class for discrete manufacturing operations.

An OEE of 60% is typical for many discrete manufacturers, but indicates substantial room for improvement.

An OEE of 40% is not uncommon for manufacturers without OEE tracking and easily achievable through fundamental measures.

Below 40% indicates significant operational issues requiring immediate attention.

Tracking OEE over time reveals patterns: which lines underperform on which shifts, which products generate the most scrap, which changeovers consume the most clock.

But the number alone is not the goal. The goal is the decisions that the number enables.

Real-time data collection — no more waiting for end-of-shift reports or manual data entry.

Automatic calculation of availability, performance, and quality — eliminating manual errors and inconsistencies.

Drill-down analysis — understand not just that OEE dropped, but why, which line, which shift, which product, which root cause.

Pareto analysis of stoppages — focus improvement efforts where they will have the biggest impact.

Cross-plant benchmarking — see how each line performs against the best line in the network.

Integration with existing systems — Allie connects to SCADA, MES, ERP, and historians, so OEE is calculated from the same data your team already trusts.