Each facility tracked machine efficiency using different spreadsheet templates and subjective operator notes. Micro-stoppages lasting under three minutes were rarely logged, yet cumulatively destroyed over fifteen percent of daily production capacity. Executive leadership lacked a standardized method to compare press performance across plants or identify whether throughput losses stemmed from mechanical faults, raw material defects, or slow die-changeovers.
Engineering Real-Time OEE Analytics for Multi-Site Automotive Component Plants
A tier-one supplier of precision automotive stampings sought to standardize Overall Equipment Effectiveness tracking across twelve stamping presses operating across three regional facilities.
Challenge
Solution
FlipWorks built a centralized, web-based OEE analytics platform. The application interfaces directly with press controllers via Modbus TCP and MQTT protocols to capture stroke counts, press speeds, and error codes continuously. The system automatically categorizes stoppages, calculates Availability, Performance, and Quality scores in real time, and sends instant mobile alerts to maintenance teams when press speeds drop below baseline parameters.
Result
- Standardized OEE calculation formulas across all twelve stamping presses and three regional plants.
- Captured short micro-stoppages automatically, giving maintenance engineers precise downtime root-cause data.
- Eliminated manual spreadsheet collation for plant managers, saving over ten hours of administrative work per manager each week.