Frequently asked questions

OEE is the benchmark metric that measures the real effectiveness of a production line or machine. It combines three factors, availability, performance and quality, into a single percentage that expresses how much of your time is genuinely productive. Our complete OEE guide breaks down each component in detail.

OEE is built from three rates multiplied together. Availability measures run time against required time, performance compares the actual rate to the theoretical rate, and quality relates good parts to total parts produced. Acting on any one of these three levers raises overall OEE.

An OEE of 85% is considered world-class for discrete production. The real average across factories often sits between 45% and 65%, which leaves significant room for improvement. The goal is not an absolute figure but steady, measured progress from your own starting point.

These three metrics differ by the time base they use. OEE relates productive time to planned production time, OOE (Overall Operations Effectiveness) factors in all scheduled time, and TEEP (Total Effective Equipment Performance) measures against the full calendar (24/7). OEE remains the most common metric for steering a line day to day.

Real-time production monitoring means automatically collecting machine data (rate, stops, scrap) to the second, with no manual entry. Operators and managers see the true state of every line continuously, so they can react to losses as they happen rather than after the fact. It is the foundation of any OEE improvement program.

The IIoT refers to connecting production equipment to a network so it automatically reports its data. In practice, sensors and connected boxes turn isolated machines into usable real-time data sources. TeepTrak applies the IIoT to performance monitoring in a plug-and-play way, with no PLC or heavy integration required.

A micro-stop is a brief interruption, often under a few minutes, that goes unnoticed during a manual reading. Added up, these micro-stops frequently account for a large share of OEE losses. At Hutchinson, they made up close to a third of the OEE gap, invisible until second-by-second sensor measurement revealed them.

Production digitalization means replacing paper logs and spreadsheets with automatic, centralized collection of shop-floor data. It delivers a reliable, shared view of performance, a prerequisite for any effective continuous improvement or Lean program. It is often the first concrete step toward Industry 4.0.

Condition-based maintenance triggers interventions based on the real state of equipment rather than a fixed schedule. By continuously tracking stops, rates and machine signals, you can anticipate drifts before a breakdown occurs. This reduces unplanned downtime and extends line availability.

Planned downtime is scheduled (maintenance, changeover, breaks), while unplanned downtime is unexpected (breakdown, material shortage, adjustment). Only unplanned downtime directly penalizes availability in the OEE calculation. Clearly distinguishing the two is essential to target the right actions.

Lean Manufacturing aims to eliminate waste so you produce more with less. OEE is its key metric: it makes the availability, speed and quality losses that Lean targets visible and quantifiable. Without a reliable OEE measure, a Lean program advances blindly.

TPM is an approach that involves both operators and maintenance teams in keeping equipment reliable and well maintained. OEE serves as its central metric for tracking gains. Automated monitoring provides the objective data needed to steer a TPM initiative.

The Six Big Losses, formalized by Nakajima in 1988, group OEE losses into six families: breakdowns, setup and adjustments, micro-stops, reduced speed, process defects and startup losses. Each loss maps back to one of the three OEE components. It is a powerful framework for prioritizing improvement actions.

Yes. For discrete manufacturing (counted parts), OEE is calculated on the number of good parts. For continuous or batch processes (chemicals, liquid food and beverage), you reason in terms of throughput, volume or time. ProcessTrak is designed to monitor these continuous processes.

OEE is calculated by multiplying its three components: OEE = Availability x Performance x Quality. For example, 90% availability, 95% performance and 99% quality give an OEE of 84.6%. Our calculator and our OEE guide walk through this calculation step by step.

Availability is the ratio of actual run time to required time (operating time minus planned stops). Formula: Availability = Run time / Required time. It drops with every breakdown, changeover or unplanned material shortage.

Performance compares actual output to what the machine should have produced at its nominal rate during run time. Formula: Performance = Actual rate / Theoretical rate. Micro-stops and slow cycles are the main factors that erode it.

The quality rate relates good parts to the total number of parts produced. Formula: Quality = Good parts / Total parts produced. Scrap, rework and startup losses all pull it down.

ISO 22400-2 defines the key performance indicators (KPIs) for manufacturing operations management, including OEE. It provides an international, standardized framework for calculating and comparing performance. TeepTrak aligns its calculations with this reference.

Yes. The international reference is ISO 22400-2, which standardizes the definitions of manufacturing KPIs, including the time states used to compute OEE. Following a common standard ensures OEE is calculated consistently across machines and sites. TeepTrak builds its calculations on these standardized definitions.

The Six Big Losses model, formalized by Nakajima in 1988, classifies OEE losses into six categories: breakdowns, setup and adjustments, micro-stops, reduced speed, process defects and startup losses. Each loss attaches to one of the three OEE components. It is a powerful analytical framework for prioritizing actions.

There is no minimum threshold: what matters is measuring your real current OEE, which serves as your baseline. Many factories discover a starting point lower than they expected, because manual readings miss micro-stops. A reliable automatic measurement immediately reveals the first pockets of gain.

Manual readings systematically underestimate losses: micro-stops are not recorded, causes are approximate and data entry is delayed. The reported OEE then looks better than reality. Second-by-second sensor measurement corrects this bias and reveals the true improvement levers.

Start from your measured OEE, identify the weakest component (availability, performance or quality), and set a step-by-step improvement target. Aiming for a few points of gain each quarter is more effective than a distant overall goal. Real-time monitoring lets you check progress against targets day by day.

No. An OEE above 100% signals a configuration error, most often an underestimated theoretical rate. The right reflex is to review the machine's nominal reference rate. An automated calculation prevents these inconsistencies.

Planned stops (breaks, preventive maintenance, no demand) are removed from required time and therefore do not penalize OEE. They are, however, captured by broader metrics that measure use of total scheduled time. Clearly separating required time from operating time is essential.

Material yield or the yield of a single step measures only one aspect, whereas OEE aggregates availability, performance and quality into a single overall effectiveness metric. OEE therefore gives a complete view of an asset's efficiency. That is why it serves as the benchmark steering metric.

A reliable comparison requires consistent time and rate definitions, aligned with a standard such as ISO 22400-2. TeepTrak standardizes collection and calculation, which makes OEE comparable across lines, workshops and plants. Multi-site leaders gain an objective internal benchmark as a result.

You improve OEE by acting on its weakest component, identified from reliable data. That means reducing downtime, tackling micro-stops, optimizing changeovers (SMED) and controlling quality. The first step is always to measure precisely so you target the right levers.

First, make every stop visible with its exact cause, then analyze the most frequent or longest causes. The real-time monitoring in PerfTrak automatically timestamps and categorizes stops. Teams can then prioritize action on the downtime that hurts most.

SMED (Single-Minute Exchange of Die) is a method for reducing changeover and tool-change times. It works by moving as many operations as possible outside the machine stop. At Nutriset, tackling changeovers with SMED helped cut changeover time and gain 18 OEE points in four weeks.

Micro-stops can only be addressed once they are measured: their short duration makes them invisible to manual readings. Second-by-second sensor measurement reveals their frequency and location. You then act on the recurring causes (jams, sensors, adjustments) to recover performance.

Root cause analysis aims to trace a problem back to its true origin rather than treating its symptoms. Precise, categorized stop data feeds methods such as the 5 Whys or Ishikawa diagrams. TeepTrak supplies the factual history these analyses need.

Operators get on board when they see the concrete value of the data and can qualify stops themselves through a simple interface. Shop-floor screens (andon) showing the target versus actual in real time strengthen engagement. MoniTrak makes these indicators visible right on the line.

An andon is a visual display that signals a line's status in real time and raises an alert when there is a problem. It speeds up team response and makes performance transparent to everyone. MoniTrak turns any screen into an andon connected to TeepTrak data.

Gains depend on the starting point, but improvements of 10 to 30 points are documented on lightly instrumented lines. Hutchinson went from 42% to 75% OEE, a gain of 33 points, across 40 sites. Nutriset gained 18 points in four weeks on a packaging line.

The first pockets of loss surface within the first days of measurement, because micro-stops and hidden causes become visible immediately. Concrete gains are often achieved within a few weeks. Nutriset documented 18 points gained in just four weeks.

You prioritize by ranking losses by impact, using a Pareto chart of stop causes and speed drops. This focuses effort on the 20% of causes that drive 80% of the losses. TeepTrak generates these rankings automatically from real data.

Indirectly, yes: fewer stops and less scrap mean less energy wasted per unit produced. Tracking performance also highlights equipment running idle or over-consuming. Some plants pair this data with energy monitoring to support their decarbonization goals.

Gains are sustained through daily management: short interval reviews, visible targets and real-time gap tracking. Without continuous measurement, old losses gradually creep back. The TeepTrak dashboard anchors performance in your teams' everyday routine.

Yes. TeepTrak is designed to install on 100% of machines, whatever their age, brand or level of automation, with no heavy modification. Non-intrusive sensors let you equip both legacy machines and recent lines. This is one of the main advantages of our plug-and-play approach.

Installation is fast: a TeepTrak box can be up and running in under one hour and start collecting usable data. No work on the PLC or reprogramming is needed in most cases. You get your first OEE indicators on the very day of installation.

No. TeepTrak can run without access to the PLC, using external sensors that detect cycles and stops. When a PLC or signal is available, we can also connect to it for finer detail. This flexibility lets you equip any kind of machine fleet.

Sensors detect machine cycles, rates and stops, then a connected box transmits this data to the platform to the second. Detection is non-intrusive and does not disrupt production. This fine-grained measurement is what makes it possible to capture micro-stops.

Yes. The boxes can run on a local network and buffer data during an outage, with no loss. Synchronization resumes automatically when the connection is restored. This guarantees continuous measurement even in poorly covered workshops.

The prerequisites are minimal: a power supply and network access to report the data. Our turnkey solutions are designed to be installed even without advanced technical skills. Our teams support the analysis of your infrastructure to ensure optimal installation.

No, deployment does not require a dedicated IT team. Installation is deliberately simple and can be carried out by your production teams with our support. This is a major difference from traditional MES projects, which are often heavy on the IT side.

Collection of rates and stops is automatic, with no data entry. Operators only step in to qualify the cause of a stop through a simple touchscreen interface, which enriches the analysis. This split keeps the workload low while improving data accuracy.

TeepTrak dashboards are accessible from a web browser on computer, tablet or smartphone, as well as on shop-floor screens. Each profile (operator, manager, leadership) sees the views suited to their needs. Data is therefore available everywhere, in real time.

Yes, as a complement to real-time monitoring. Our Machine Learning module mines historical data to detect patterns, anticipate drifts and support decisions. AI enriches the reliable data collected, it never replaces it.

There is no practical limit: TeepTrak scales from a single pilot machine to hundreds of lines across multiple sites. The architecture is modular and grows at the pace of your needs. Hutchinson runs the solution across 40 sites in 12 countries.

Yes, and it is often recommended. A pilot on one line proves the value quickly, lets you refine usage and builds the business case before a wider rollout. The simplicity of installation makes this start very fast.

An MES (Manufacturing Execution System) is a broad system that handles scheduling, traceability, quality and execution, often long and costly to deploy. An OEE tracking solution like TeepTrak focuses on real-time performance measurement and installs in a matter of hours. The two are complementary: TeepTrak can feed reliable performance data into an MES.

For performance tracking and OEE improvement, TeepTrak delivers most of the benefits without the complexity of a full MES. Many manufacturers start with TeepTrak to get fast results, then decide whether a broader MES is needed. TeepTrak can also coexist with and enrich an existing MES.

Yes. Our modules integrate with most ERP, MES, CMMS, Power BI and other market applications for centralized data management, including SAP and Oracle. Performance data flows automatically into your existing systems. This avoids double entry and makes your indicators more reliable.

Yes, TeepTrak provides dedicated APIs to exchange data with your existing systems. You can export OEE, stops and volumes to an ERP, a data lake or a BI tool. Integration stays simple and well documented.

OPC UA is an industrial data-exchange standard that communicates with modern PLCs and equipment. TeepTrak offers a PerfTrak OPC UA variant to collect data directly via this protocol. It is ideal for fleets that are already instrumented and standardized.

Yes. TeepTrak data can be exposed to Power BI or other business intelligence tools for tailored dashboards. You can combine machine performance with your other enterprise indicators. The data stays consistent and up to date.

Yes. The stop events and machine signals reported by TeepTrak can feed a CMMS to trigger or prioritize maintenance interventions. This brings performance tracking and maintenance management closer together. The result is better equipment availability.

Exchange happens via API, structured exports or industrial protocols such as OPC UA, depending on your architecture. We adapt the integration mode to your existing environment. The goal is smooth, automatic data flow with no re-keying.

In most cases, no: TeepTrak adapts to your existing network with limited requirements. Our teams analyze your infrastructure to define the most suitable and secure reporting mode. Integration is designed to be as non-intrusive as possible.

Yes. The platform consolidates indicators from multiple lines and plants into multi-site dashboards. Industrial leaders can compare performance and spread best practices. Standardized calculation makes these comparisons reliable.

Yes. You can export your OEE, downtime and production data through the API or dedicated exports. Your teams remain free to reprocess it in their own tools. Your data belongs to you and stays accessible.

Basic monitoring is live within hours, and integrations to ERP, MES or BI are then rolled out in stages. This progressive approach avoids long, risky projects. You get value before the advanced integrations are even finished.

PerfTrak is TeepTrak's solution for real-time performance monitoring and OEE calculation. It automatically measures availability, performance and quality, and categorizes stops to reveal losses. It is the ideal starting point for an OEE improvement program.

QualTrak digitizes quality controls right on the production line. It replaces paper sheets with guided, traceable checks and links quality directly to OEE. Non-conformities are detected and documented earlier.

PaceTrak tracks the performance of manual workstations and tasks, where there is no machine to instrument. It measures the cycle times and durations of manual operations to balance and optimize work. It is the answer for labor-intensive workshops.

ProcessTrak is dedicated to monitoring continuous and batch processes, such as in chemicals or liquid food and beverage. It adapts OEE logic to throughput and volumes rather than individual parts. It gives a fine-grained view of continuous-process efficiency.

MoniTrak displays industrial KPIs in real time on shop-floor screens. It turns any screen into a connected andon that shows target versus actual to every team. Performance becomes visible and shared on the floor.

The Machine Learning module mines historical data to detect patterns and anticipate performance drifts. It supports decisions by surfacing correlations that are hard to spot manually. It adds to the monitoring solutions to take analysis further.

PerfTrak OPC UA is the variant of PerfTrak that collects data via the industrial OPC UA standard. It suits fleets already instrumented and standardized around this protocol. You get TeepTrak OEE tracking with no extra sensor when the data already exists.

For most manufacturers, PerfTrak is the natural entry point to measure and improve OEE. You then add QualTrak for quality, PaceTrak for manual workstations or ProcessTrak for continuous processes. Explore the full range on our solutions page.

Yes. PerfTrak, QualTrak, PaceTrak, ProcessTrak and MoniTrak share the same platform and the same data. You can combine them to cover performance, quality, manual tasks and display in one consistent whole. Deployment stays modular, module by module.

Yes. Each solution is standalone and delivers value on its own, for example PerfTrak for OEE tracking alone. You add other modules at the right time, without deploying everything at once. This modularity keeps both investment and change management under control.

Yes, that is the role of MoniTrak, which broadcasts indicators on shop-floor screens. Operators continuously see the target, rate and performance. This shared visibility supports team management and engagement.

Yes, through QualTrak, which digitizes quality controls and links them to OEE. Quality is no longer tracked separately: it becomes a component steered in real time alongside performance. You detect and correct drifts earlier.

Yes, thanks to PaceTrak, designed for manual workstations and tasks with no machine to instrument. It measures cycle and operation times to balance workstations and reveal losses. It is the right solution for activities with a strong human component.

Yes. Our ROI calculator estimates the potential return on investment of digitizing your production monitoring in a few clicks. You get an order of magnitude of the gains before any commitment. It is a good starting point to build your business case.

The return on investment of an OEE tracking solution is most often between 3 and 12 months. It comes from capacity gains, reduced downtime and less scrap, with no machine investment. Our ROI calculator lets you estimate this return for your own case.

You compare the expected gains (OEE points recovered, extra capacity, lower scrap) to the cost of the solution. A few OEE points on a bottleneck line are often enough to pay back the project quickly. The more critical the instrumented line, the faster the ROI.

Hutchinson, a tier-1 automotive supplier, went from 42% to 75% OEE across 40 sites in 12 countries. Nutriset gained 18 OEE points in four weeks on a packaging line, with a return on investment of under one month. These are verified customer results.

No, and that is the whole point: OEE tracking reveals the hidden capacity of your current machines. You recover productive time by removing losses, without buying equipment. It is often a factory's best investment in terms of gain per cost.

Yes. Every OEE point recovered equals capacity gained on machines already in place. On a bottleneck line, this can avoid or postpone an expansion investment. The freed capacity translates directly into potential revenue.

Payback typically occurs within a few months, in a range of 3 to 12 months depending on the context. In very favorable cases, such as Nutriset, the return on investment was under one month. The speed of installation accelerates the return accordingly.

Rely on the measured OEE, the quantified losses and the recoverable capacity, translated into financial value. A pilot on a critical line provides concrete proof and a real ROI calculation. Our calculator and our customer stories support this case.

ROI depends mainly on how critical the instrumented lines are and the scale of the initial losses, more than on size. An SME and a large group alike can achieve fast returns. Modular deployment lets you align investment with the expected value.

Yes, provided you maintain daily management backed by real-time data. Short interval reviews and visible targets anchor the gains over the long term. Without continuous measurement, losses tend to reappear.

Our customer stories detail the context, actions and results achieved by our clients. You will find documented OEE improvements by sector. It is a useful basis for estimating your own potential.

Yes. Automotive, demanding on both rate and quality, gains strongly from real-time OEE tracking. Hutchinson, a tier-1 supplier, went from 42% to 75% OEE across 40 sites. Explore the Automotive & Mobility sector.

Yes. Food and beverage combines fast lines, frequent changeovers and hygiene requirements, where OEE tracking reveals significant gains. Nutriset gained 18 points in four weeks by tackling changeovers. See the Food & Beverage sector.

Yes. Pharmaceuticals, cosmetics and medical require traceability and process control, which QualTrak and PerfTrak reinforce. Real-time tracking reliably documents performance and quality. See the Pharma, Cosmetics & Medical sector.

Yes. These high-value, small-batch sectors benefit from precise tracking of availability and operation times. Measurement reveals losses on costly assets such as CNC machines. See the Aerospace, Defense & Naval sector.

Yes. Electronics, with its fast SMT lines and numerous micro-stops, benefits particularly from second-by-second measurement. Tracking reveals speed losses that are otherwise invisible. See the Electronics & Electrical sector.

Yes. These process industries, often continuous and energy-intensive, gain from tracking availability and performance continuously. ProcessTrak is suited to these processes. See the Building Materials, Glass & Mineral sector.

Yes. By automatically recording performance, stops and quality checks, TeepTrak builds a reliable, timestamped history aligned with ISO 22400-2 and ready for ISO 9001 and customer audits. This traceability supports audits and compliance programs. QualTrak reinforces this on the quality side.

Yes. Our solutions serve industrial companies of all sizes, from SMEs to large groups, across every sector. Modular deployment adapts to each one's budget and maturity. An SME can start on one line, a group across dozens of sites.

TeepTrak applies high-level security protocols: data is encrypted and stored on secure servers, in line with the strictest standards. Access is controlled by profiles and permissions. Your production data is protected end to end. Learn more on our Security & Trust page.

Yes. TeepTrak respects the GDPR framework (and aligns with CCPA) for the data concerned. The solutions are designed to collect mainly machine and performance data, limiting personal data. Our privacy practices govern collection and processing.

Your data belongs to you. TeepTrak collects it and makes it available to you, and you can export it via the API or dedicated exports. You retain control over your industrial data assets.

Data is hosted on secure servers, with options suited to your localization and compliance requirements. We discuss the architecture best aligned with your security policy. The goal is to balance accessibility and protection.

Yes. Information is encrypted to guarantee its confidentiality, both in transit and at rest. This encryption is part of TeepTrak's standard security protocols. It protects your data against any unauthorized access.

Yes. Access to dashboards is managed by profiles, with views tailored to each role (operator, manager, leadership). This ensures everyone sees the relevant, authorized information. Access governance stays under your control.

Depending on your security policy, architectures that limit or control cloud reporting can be studied. The boxes already operate on a local network with data buffering. We adapt the deployment mode to your constraints.

For sensitive sectors, we adapt the architecture, hosting and access management to your compliance and confidentiality requirements. Data traceability supports regulatory audits. Contact our teams to scope these specific needs.