MES & OEE FROM THE EXPERTS
Improve OEE and Reduce Costs
Improving OEE means systematically identifying and reducing production losses related to availability, performance and quality. Real-time data, downtime analyses, fault causes and scrap data provide a reliable foundation for using existing equipment more efficiently, reducing costs and prioritizing improvement measures based on data. GAMED supports companies with MES, OEE and shopfloor solutions for industrial production.
- DOWNTIME reduced systematically
- LOSSES made visible
- EQUIPMENT used more efficiently
Why Manufacturing Companies Lose Potential
Many manufacturing companies have modern machines and experienced employees. Yet important questions often remain unanswered:
- Why is a production line not achieving its planned performance?
- Which downtime events cause the greatest losses?
- Where and why do quality losses occur?
- Which shift or machine operates particularly efficiently?
- Which measures deliver the greatest benefit?
The required information is often available, but distributed across different systems such as Excel files or machine controls. As a result, companies lack transparency across their entire equipment base and an objective foundation for improvement.
The consequences:
- Hidden production losses
- Inefficient processes
- Unnecessary costs due to rescheduling, additional work, scrap, etc.
- Unused capacity
- Difficult prioritization of continuous improvement projects
Why This Becomes Costly
Every minute of downtime costs money.
In addition to major equipment failures, many small losses in day-to-day operations cause significant additional costs:
- Short unplanned downtime events
- Reduced machine speeds
- Long changeover and cleaning times
- Quality deviations
- Errors caused by manual data entry
- Lack of root cause analyses
Only by accurately and completely recording processes across all equipment can improvement potential become visible and provide a basis for targeted measures. The impact of each measure is then verified based on performance development.
How GAMED Helps
GAMED helps manufacturing companies make production losses visible and continuously reduce them.
Our solutions capture machine, operational and production data in real time and make it clearly available to production, quality management, maintenance, Lean Management and management.
The key functions:
- Automatic data acquisition – Automatically captured data reduces the workload for employees and significantly improves data quality.
- Real-time OEE – Availability, performance and quality are calculated and visualized automatically.
- Loss analysis – Downtime, performance losses, scrap and rework are automatically detected, classified and analyzed.
- Make loss causes transparent – Identification of the greatest OEE losses by cause, machine, product or shift.
- Production monitoring – Live dashboards provide transparency into current production status and potential deviations.
- Shift and line comparison – Compare machines, teams and production areas based on objective data.
- Data-driven improvement – Improvement measures are prioritized based on actual production data.
- Integration of existing systems – Connect machines, PLCs, ERP systems and existing IT environments.
Specific Benefits
A systematic OEE analysis provides companies with the foundation for sustainable improvement.
Typical results:
- Greater transparency for equipment operators and management
- Production losses become visible and measurable.
- Deviations from plan are identified in real time.
- Better utilization of existing equipment capacity
- Reduced quality costs
- Less rescheduling and better adherence to delivery dates
- Priority-driven continuous improvement and Lean projects
- Reduced manufacturing costs per unit
“By digitalising our production processes with GAMED, we were able to increase both system performance and system availability by over 10%.”
Ludwig Klinger Controlling
“Thanks to the seamless system integration, we have achieved measurable increases in efficiency, improved the quality of our systems and at the same time significantly reduced the workload for our employees.”
Christian Braun Head of Operational Excellence
Frequently Asked Questions about OEE, Downtime and Production Losses
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What Does OEE Mean?
OEE (Overall Equipment Effectiveness) describes the overall effectiveness of production equipment. The KPI consists of availability, performance and quality. TEEP (Total Effective Equipment Performance) additionally includes utilization losses, which essentially represent planned non-production time. OEE is important for the production team, while TEEP helps management identify additional performance potential.
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Why Is OEE Important?
OEE makes production losses visible and helps identify the actual causes of efficiency losses.
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What OEE Values Are Considered Good?
The optimal OEE depends on the industry, process and order structure. Rather than focusing on a universal target value, continuous improvement based on reliable data is what matters most.
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What Data Is Required for OEE?
Typically, machine states, production quantities, quality data and shift information are used.
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Can Existing Machines Be Integrated?
Yes. GAMED solutions support machine connectivity in different ways, including signal acquisition, OPC UA, database connections, etc.
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How Quickly Can an OEE Project Get Started?
Many projects begin with a pilot project on a single machine or production line. After approximately two weeks of preparation, the pilot installation can become operational.
