OEE & Production Monitoring
Live OEE — no manual data collection, no end-of-day surprises
Why OEE & Production Monitoring?
Intellyx OEE Monitoring is a real-time production tracking module that calculates Overall Equipment Effectiveness (OEE) across Availability, Performance, and Quality dimensions for each machine and production line in an Indian factory. It connects to PLCs, sensors, and existing ERP systems to collect production data automatically, eliminating manual shift reporting. Downtime events are detected and categorised within minutes, and automated shift reports are delivered daily without any manual input from supervisors or production engineers.
Most Indian factories know their end-of-month OEE. Intellyx gives you your OEE right now — for every machine, line, and shift. The system pulls data from PLCs and sensors automatically, tracks production against targets in real time, and flags variance before a shift ends rather than after it. Supervisors and plant managers receive automated shift reports via WhatsApp and the Intellyx dashboard, eliminating the 3-hour manual reporting cycle that consumes quality and production staff every day. Multi-plant deployments get a unified view with standardised KPIs across all sites.
What OEE & Production Monitoring Does
Core capabilities that make the module production-ready from day one.
Live OEE Dashboard
OEE is calculated and displayed in real time for each machine, line, and plant — broken down into the three components: Availability (planned vs actual runtime), Performance (actual vs ideal speed), and Quality (good parts vs total parts). No manual data entry required.
Automatic Downtime Categorisation
The system detects machine stoppage within minutes and prompts the operator to categorise the downtime reason (breakdown, changeover, material shortage, planned maintenance). This builds a structured downtime database that drives maintenance prioritisation and line balancing decisions.
Production vs Target Tracking
Production counts are compared against shift targets in real time with colour-coded variance alerts. When a line falls behind target by a configurable percentage, supervisors receive an immediate alert — not a report at the end of the shift.
Automated Shift Reports
Shift reports covering production output, OEE breakdown, downtime events, and quality data are generated automatically at shift end and distributed via WhatsApp and email. This eliminates the manual reporting workload for production supervisors and quality engineers.
Multi-Plant Visibility
For manufacturing groups with multiple plants, Intellyx provides a unified OEE dashboard with standardised KPIs across all facilities. Plant managers can drill down from group-level performance to machine-level data without switching systems or waiting for consolidated reports.
ERP and PLC Integration
Production data is pulled directly from PLCs, sensors, and existing ERP systems (SAP, Tally, ERPNext) without manual data transfer. Sales orders and production targets from ERP flow into the monitoring dashboard automatically, creating a single source of truth for the production floor.
How OEE & Production Monitoring Gets Deployed
A structured deployment process that minimises disruption and delivers results within the first 90 days.
Connect PLCs and Data Sources
Intellyx connects to machine PLCs, existing sensors, and ERP systems using standard industrial protocols (OPC-UA, Modbus, MQTT) and ERP APIs. Machines without PLCs are connected using retrofit IoT sensor kits. Connection takes 1–2 weeks depending on the number of machines and data sources.
Configure Production Hierarchy
The production hierarchy — plant, line, work centre, machine — is configured in the Intellyx platform along with shift schedules, planned downtime windows, and production targets. This configuration drives OEE calculation and variance alerting logic.
Baseline Calibration
The system runs for 1–2 weeks to establish baseline performance metrics for each machine and line. This baseline is used for downtime anomaly detection and for calculating Performance OEE based on actual vs ideal cycle times.
Go Live with Dashboards and Alerts
Live OEE dashboards are activated on the Intellyx platform, accessible from any browser or mobile device. Shift report distribution and alert routing are configured for supervisors, plant managers, and senior management based on their role and location.
OEE & Production Monitoring Across Industries
How manufacturers in different sectors put this module to work.
Stamping, welding, and assembly lines are monitored for OEE with automatic detection of die-change downtime, breakdown events, and speed loss. Real-time variance alerts allow shift supervisors to respond to line slowdowns before they impact daily production targets.
Loom-wise OEE monitoring tracks weaving efficiency, yarn break stoppages, and planned maintenance across multi-plant operations. A unified dashboard allows the COO or plant head to compare plant performance without waiting for weekly spreadsheet reports.
Tablet press, coating, and packaging line OEE is monitored in real time with GMP-compliant audit trails for each production run. Downtime categorisation feeds directly into deviation reports required by regulatory auditors.
SMT line OEE monitoring tracks component placement throughput, changeover time, and first-pass yield in real time. Production managers can see whether each SMT line is on track to meet daily build targets without walking the floor.
Common Questions About OEE & Production Monitoring
What is OEE and why does it matter for Indian factories?
OEE (Overall Equipment Effectiveness) is a standardised metric that measures how effectively a manufacturing operation uses its equipment, expressed as a percentage of the theoretical maximum output. It is calculated as the product of three factors: Availability (what percentage of planned production time the machine is actually running), Performance (how fast the machine runs compared to its ideal speed), and Quality (what percentage of output is first-pass good parts). For Indian factories, OEE is critical because low OEE represents direct revenue loss — a machine running at 60% OEE is losing 40% of its potential output every shift. Identifying and addressing the specific OEE loss drivers (breakdowns, speed loss, quality rejects) is the fastest path to capacity improvement without capital expenditure.
How does Intellyx collect OEE data without manual input?
Intellyx connects directly to machine PLCs and retrofits IoT sensors on machines without existing connectivity to automatically capture production counts, runtime, and stoppage events. Production targets and shift schedules are pulled from your existing ERP system. The combination eliminates the need for operators or supervisors to manually record production data, which is the primary source of OEE inaccuracy in most factories. When a machine stops, the system detects it within minutes and prompts the operator for a downtime reason via a simple tablet interface — no paper forms required.
Can Intellyx monitor OEE across multiple plants?
Yes. Intellyx supports multi-plant OEE monitoring with a unified dashboard that displays group-level, plant-level, line-level, and machine-level OEE in a single view. Each plant can have its own shift schedules, target configurations, and alert routing while contributing to the consolidated group view. This is particularly valuable for manufacturing groups where the COO or operations director needs to compare performance across factories without relying on each plant to send manual weekly reports. The standardised KPI framework also enables meaningful benchmarking between plants for the first time.
How quickly does Intellyx detect downtime events?
Intellyx detects machine stoppages within 5 minutes of occurrence in standard deployments — compared to the industry average of 4–6 hours when downtime is reported manually at shift handover. For machines connected via PLC, detection is near-instantaneous (within 30 seconds). When a stoppage is detected, an alert is sent to the supervisor and maintenance team immediately via WhatsApp and the Intellyx dashboard. This speed of detection is the primary driver of the downtime reduction outcomes seen by Intellyx customers.
More questions? Talk to the Perimattic team
Deploy OEE & Production Monitoring In Your Factory
Perimattic starts with a scoping call to understand your specific challenges — then provides a practical deployment plan and ROI estimate before you commit.