Digital Workshop Build-out for an Equipment Manufacturer

This high-mix, low-volume equipment manufacturer runs 60 key machines. Equipment status depended on manual patrols and paper logs, downtime reasons were never categorised, OEE was estimated rather than measured, and the monthly equipment report took three days of manual work.

Scope

1. Data acquisition: industrial gateways connected to 60 machines, with protocol conversion and unified modelling for CNC, welding and assembly equipment.

2. OEE framework: availability, performance and quality decomposed by machine, team and product family, with structured downtime reasons.

3. Exception management: andon calls, response timing, and automatic escalation to team leaders and the maintenance supervisor.

4. Dashboards: plant, team and machine level views showing exceptions and attainment in real time.

5. Energy monitoring: meters on key machines, with consumption allocated by product and shift.

Results

OEE up from 58% to 71%, average exception response cut from 22 minutes to 6, the monthly equipment report generated automatically instead of three days of manual work, and downtime causes quantified for the first time. The project ran 12 weeks.

Our role

Digital workshop blueprint, machine connectivity design and OEE metric definition, plus help establishing the exception response mechanism and dashboard usage standards, and four rounds of team training after go-live.