Every year, hundreds of manufacturers invest in OEE software to improve their performance. Yet over 65% of these projects fail, because they collect data without ever transforming operators into true performance drivers. The real challenge is not to measure the overall efficiency of equipment – it’s to make it act in the field, in real time.
Why OEE Projects Fail: Identifying Lost Productivity
Manufacturers end up with sophisticated dashboards that only data analysts understand, while operators work blind. Three fatal errors: confusing data collection with improvement (a 58% OEE displayed in an office makes no difference if the operator has no visibility), heavy IT projects requiring 6 to 18 months of integration, and forgetting the end-user, who should be able to use the tool easily. These problems create ongoing productivity losses that could have been avoided.
5 Criteria for Reducing Losses and Achieving Your Business Goals
Rapid deployment: Installation in less than 2 weeks, machine connection without heavy IT development, operator training in 1-2 days. Red flag: if the vendor talks about a “3-month scoping phase”, your project could get bogged down.
Operator accessibility: intuitive field interface, easy-to-understand visual alerts, simplified downtime declaration. OEE doesn’t improve in the office – it improves on the production line with the right user interface.
Measurable ROI: ROI in less than 6 months with concrete customer cases and metrics, methodology for continuous improvement, quantifiable gains in product quality.
Machine connectivity: native compatibility, ability to start with manual input and gradually automate production processes, modular architecture.
Support: In-the-field training, responsive technical support, improvement methodology, knowledge-sharing between users.
Top 5 OEE Software
1. Integrated MES solutions
Global vision with ERP integration, multi-site standardization, process compliance, scalability. Limitations: 12-24 months deployment, investment 150-500k€, complexity requiring IT resources. Ideal for large groups with 500+ employees.
2. General IIoT platforms
Modular architecture, AI and predictive analytics, extensive connectivity. Limitations: Technical expertise required, 6-12 months before operation, cost 80-300k€. Ideal: Manufacturers with a complete IIoT vision.
3. BI Manufacturing tools
Powerful visualization, multiple data sources, widespread skills. Limitations: Requires existing data, retrospective view, cost 30-100k€. Ideal: Companies with existing collection infrastructure.
4. OEE Legacy specialists
Industry expertise, proven reliability, established community. Limitations : Outdated interface, rigid methodology, cost 15-60k€. Ideal: Industrials who value stability.
5. TEEPTRAK: Real-Time Process Improvement
French real-time OEE monitoring solution. Philosophy: operators improve performance when they see the truth in real time. Express deployment: ultra-fast production start-up, plug & play connection without downtime. In 48 hours, your lines show real-time performance. At Nutriset: 29% increase in efficiency in the first month. Field interface: understood in 15 minutes. Screens visible from line, red/orange/green alerts, declaration in 2 clicks. Speaks workshop language intuitively.
Limitations : No complete MES suite with ISO quality management. Optimized sites 3-5 lines minimum. Limited predictive analytics – priority to immediate action.
Case studies: Nutriset +29% efficiency in 1 month (OEE 62% to 80% in 4 weeks). Automotive -35% downtime in 6 weeks thanks to root cause analysis. Aerospace +18% productivity 12 sites with measured precision.
Ideal for : SMEs and SMBs with 50-1000 employees looking for fast results. Automotive, food processing, pharmaceuticals, aerospace, metallurgy. Investment: €500/month per line, ROI 1-3 months.
TEEPTRAK vs Other Solutions: Time Savings and Business Performance
Deployment: MES 12-24 months, IIoT 6-12 months, BI 3-6 months, Legacy 2-4 months. TEEPTRAK: 2-4 weeks.
Essential questions for achieving your improvement objectives
Deployment: “Time to OEE actual production?” If >2 months, dig in. “Machine modifications?” Answer no. “Plan B machines not connectable?” Check. Usage: “Operator training? Ask for demo. “OEE consultable online?” Essential. “Without internet?” OEE must continue. ROI: “3 customer cases with figures?” Demand figures. “Gain 3 months?” If they don’t answer, run away. “Included in price?” Be transparent. Support: “Transform data into action?” Good publisher brings methodology.
Conclusion: Turning Losses into Performance
The best OEE software turns operators into performance drivers. Three principles: prioritize speed (a system in 1 month is better than a perfect one in 12 months), put operators at the center (test interface with real operators), demand rapid ROI (triple investment gains in six months). TEEPTRAK: radical simplicity and immediate action. No 18-month IT project. Operators see in real time and act. +29% Nutriset performance in 1 month, hundreds of lines in France and abroad.
0 Comments