Analytics
ManufacturingUse case, no client resultFind where OEE is lost, by line and by shift.
Your daily report gives one OEE figure for the plant, a day late. It averages away the machine that stopped twice on night shift and the changeover that ran long. We show the loss where it happens, while the shift can still act on it.
OEE by line and shiftSchematic
Availability×Performance×Quality
Shift AShift BShift C
Line 1
Line 2
Line 3
Top loss this shiftReason, machine, owner. Updated as the shift runs.
4.2×Target return in 12 months
Week 1Fixed-fee audit
6 weeksTo the first live result
3Senior people on the work
TypeUse case: what we build, not a client story
ForPlant heads, production managers and maintenance leads running several lines and shifts
EngagementWeek 1 audit, then build in about six weeks, fixed scope, fixed fee
Runs onPLC, SCADA and MES signals plus your ERP (SAP or Tally), in Antvia on your own cloud
The problem
One plant figure, a day late.
Most plants know their OEE is too low. Few can say which line, which shift and which loss is pulling it down. The figure is put together from logbooks and spreadsheets the next morning, so by the time anyone sees it, the shift that lost the time has gone home.
What was broken
- OEE is reported once a day, for the whole plant, so it hides which line and shift lost the time.
- Downtime reasons are typed in after the fact, or left as "other".
- Small stops and slow cycles never reach the logbook, so performance loss stays invisible.
- Machine data, production plans and rejects sit in different systems that do not agree.
- Every meeting starts by arguing about the number, not fixing the loss.
You might be here if
- Your OEE figure comes from a spreadsheet someone fills in each morning.
- "Other" is one of your biggest downtime reasons.
- Night shift numbers look different and nobody can say why.
- You add capacity before you know how much you are already losing.
Why it mattered. Lost time on a line you already own is the cheapest capacity you will ever buy. You cannot win it back until you can see it, by line, by shift and by loss.
The approach
Count the time where it is lost.
We start on the shop floor, not in the data. In Week 1 we walk one line with your team, list every way it stops or slows, and agree the reason codes people will actually use. Then we connect the machine signals, the plan and the rejects, so availability, performance and quality are counted the same way on every line.
What you have
PLC and SCADA signals
MES and production plan
Rejects and rework logs
woodfrog method
Walk the lineAgree stops and reason codes
Join the sourcesOne record per machine, per minute
Rank the lossesBy line, shift and machine
What changes
Live OEE on the floor
Reason on every stop
Owner on every top loss
Fix the biggest loss first
Deliberately not doneReplacing your MES or PLCs, or a wall of screens nobody acts on
The solution
Live OEE your shift can act on.
What we build
- Connectors that read PLC, SCADA and MES signals without changing how your machines run.
- Downtime captured at the machine, with a short list of reason codes your operators agreed in Week 1.
- OEE split into availability, performance and quality, by line, shift and machine, updated through the shift.
- The six big losses ranked, so each morning meeting starts with the top loss and its owner.
- A plant view joined to your ERP (SAP or Tally), so lost hours carry a cost, not just a percentage.
- Everything in Antvia on your own cloud, on open formats, so your team can change it without us.
One line goes live first. Once the reason codes hold up there, the same setup rolls out line by line. If Uloborus already runs your operations, it reads the same set of records.
How it would runOperate is open-ended and drawn at one week only to fit. Further lines roll out after the first one holds up.
Wk 1Wk 2Wk 3Wk 4Wk 5Wk 6Wk 7
Audit
Walk one line
Build
Connect, count, rank the losses
Operate
Ongoing
Wk 1Wk 2Wk 3Wk 4Wk 5Wk 6Wk 7
Audit
Walk one line
Build
Connect, count, rank the losses
Operate
Ongoing
The impact
What we would measure.
Where a typical line loses its timeWhere the time goes between planned time and OEE.
Illustrative, commonly cited figuresPlanned timeAvailability lossPerformance lossQuality lossOEE
Many plants run near 60% OEE. The gap to 85% hides in downtime, slow cycles and rejects. We make each loss visible by line, shift and machine. These are commonly cited industry figures, not a woodfrog result.
What we would measure on a real engagementWhat we would measure
OEE by line, shift and machineAgainst your own baseline from Week 1
Downtime with a real reason codeShare of stops no longer logged as "other"
Top three lossesEach with a named owner and a date
Hours won backCosted through your ERP, not estimated
Return on the engagementTarget: at least 4.2× within 12 months, measured on your own numbers
Find the loss on your lines.A short call, or record a message. A person replies within one business day.
