OEE dashboard, one line
Pull from existing PLC tags or new sensors, calculate availability / performance / quality in real time, surface on a TV on the floor. Start with your highest-volume line.
From $9,5008:1 typical
Vertical · Plant floor, OEE
Plant-floor visibility, without the MES rollout.
Small to mid-size manufacturers in RTP and along the I-40 / I-85 corridor through Burlington, Greensboro, and Winston-Salem. PLC and SCADA experience meets back-office discipline. Real-time OEE dashboards, predictive downtime alerts, and integrations that meet your line where it lives. No "rip and replace."
The problems
Where the hours go.
Mid-sized manufacturers run a mix of decade-old PLCs, a spreadsheet, and one person who keeps the line up. The hours hide between the floor and the office.
Problem 01
OEE is a once-a-quarter exercise.
Production reports come from a paper traveler, a daily Excel rollup, and the line lead's memory. By the time you have a number, the shift it describes is two months gone.
- OEE calculated quarterly
- Downtime logged on paper
- Throughput estimated, not measured
Problem 02
Downtime surprises the morning huddle.
A bearing failure on the conveyor, a sensor drift on the filler, an over-temp on the extruder. Each one a phone call at 6 a.m. Each one preventable with telemetry that's already on the floor.
- Unplanned downtime over 8%
- Maintenance is reactive
- Sensor data exists but isn't watched
Problem 03
The floor and the office don't talk.
Production runs in the PLC, inventory in the spreadsheet, finance in QuickBooks or SAP. Reconciliation happens monthly, by hand. The plant manager and the controller disagree on Friday.
- Production not reflected in inventory same-day
- Manual data entry into ERP
- Inventory write-offs from desync
Quick Wins, manufacturing
What we ship first.
The most-shipped Quick Wins for manufacturing operators. Each one is fixed price, fixed date, scoped from the audit.
Predictive downtime alerts
Watch the telemetry you already have for the drift, the over-temp, the cycle-time creep. Alert before the failure. SMS to maintenance lead, ticket in your CMMS.
From $12,0005:1 typical
Floor-to-ERP integration
Production complete in the PLC becomes inventory receipt in your ERP within minutes. Same for scrap, rework, and WIP. Stops the manual data entry.
From $10,0006:1 typical
Paperless traveler
Replace the paper traveler with a tablet at the workstation. Operators check off steps, photo the deviations, sign off the lot. PDF-equivalent for traceability.
From $7,5004:1 typical
Multi-line aggregator
Once one line is wired, the second is faster. Common dashboard across lines, comparison views, shift-vs-shift, line-vs-line.
From $14,000Compounding
Quality inspection capture
Inspection results from gauges, calipers, or vision systems pushed into a quality module. SPC charts auto-generated. Drift caught before scrap stacks up.
From $11,0005:1 typical
Real engagement
Burlington manufacturer: 30% downtime cut, line 2, one quarter.
A specialty-chemical line in Burlington was running 14% unplanned downtime. The line had Allen-Bradley PLCs from 2014 logging plenty of telemetry, and nobody was watching it. Maintenance was reactive; the line lead was the alarm system.
The audit surfaced one big Quick Win: pull the existing telemetry, build the OEE dashboard, and add predictive alerts on three repeat offenders (the filler O-ring, the heater band, and the conveyor bearing). Five-week build, fixed price.
One quarter in: unplanned downtime is at 9.8%. The filler O-ring gets swapped on schedule now, not at 2am. The line lead got his weekends back. Next quarter, line 3.
30%
Unplanned downtime cut
$210k
Quarterly throughput recovered
3 mo
Payback on the Quick Win
0
PLC replacements required
Manufacturing Q&A
Questions specific to your floor.
The questions we hear most from manufacturing operators. For everything else, the general FAQ has more.
Do you replace my PLCs?
Almost never. We integrate with what you have. Replacing PLCs is its own engagement and we will tell you when it is needed; mostly it is not.
Do I need a full MES?
Usually no. Most of what an MES gives you, you can get from a focused dashboard and a few integrations, at 10% of the cost. We will tell you honestly if the MES math clears.
What if my telemetry is air-gapped?
We work in air-gapped environments. We can deploy on-premise, hand-off via OPC bridges, and respect ICS-CERT guidance. Compliance posture is documented up front.
Do you work with my integrator?
Yes. Often we layer on top of an existing integrator and tackle the data-and-analytics side while they handle controls. We collaborate, we do not poach.
Can you handle multi-site rollouts?
The Enterprise Audit is for that. We audit two or three sites, design a pattern, and roll out site by site with a fixed cadence.
Ready for manufacturing
Get the data off the line and into a dashboard.
The friction audit walks the floor with the line lead and the controller. Math on the page in writing. PLC stays where it is.