OptimalOEE™ Wiki / Value and deployment
Value and config
Value and deployment
What structured OEE returns, and what it takes to capture it. Value ranges first, then the sensors and infrastructure, in general terms.
Potential value
Across Optimal client engagements, structured reliability and OEE programmes return value in these ranges. They are confirmed ranges shown for context, not a per-site guarantee; where a result lands depends on the baseline and how hard the losses are worked.
Why a few points matter
Because OEE is a share of scheduled time, points convert almost directly into capacity. A line at 70% that reaches 76% is running about 8% more good output on the same asset, the same shift and the same crew. On a constrained line that capacity is either more sales or deferred capital, which is where the business case usually sits. OptimalOEE™ quantifies the losses so the points are attached to specific, fixable causes rather than a target.
What it takes: the three data streams
To calculate OEE you need three time-stamped streams per station and shift:
- Run and stop state for availability;
- A part count for performance;
- A good-or-reject signal for quality.
Everything else is context (shift, product, reason codes). The engineering question is only where those three streams come from.
Config to deliver value (general)
| Use existing signals | Where the data already exists, integrate the PLC or machine tags, the historian, SCADA or MES. Lowest friction, no new hardware. |
|---|---|
| Retrofit a sensor fleet | Where it does not, add sensing at the line: counting sensors for part counts, current or state sensors to infer run and stop, andon buttons for operator-logged stops and reasons, and door or guard contacts for changeovers. |
| Edge and connectivity | A plant-floor gateway collects the sensors. A wireless approach (for example LoRaWAN) suits brownfield retrofits with minimal cabling; wired capture direct from PLC or IO is used where sub-second precision is needed. |
| Secure ingestion and store | Readings publish over a secure channel (MQTT over TLS) to an ingestion service and into a time-stamped store, kept immutable at source for the audit trail. |
| Portal and mobile | OptimalOEE™ recomputes OEE from that store on every read and serves the portal and the Android Companion App. |
General architecture only. A site assessment sets the exact sensor selection, sampling and integration for your equipment.
A typical path
Start with one line: confirm the three data streams, stand up capture, and validate the OEE against what the crew sees. Prove the losses and the value on that line, then template the same capture across the plant. The demo runs this end to end on a seeded plant so the shape is clear before any hardware.
Where do you stand?
Before you invest, the GARPI™ benchmark shows your asset-management maturity against industry peers: an independent, ISO 55001 and GFMAM-aligned score from 0 to 100 across eight weighted dimensions and five maturity tiers, free and anonymous. It is a fast way to see where you are today, and where OptimalOEE™ moves you first. Take the GARPI™ benchmark.