In many factories, OEE data is still being manually recorded using paper or Excel spreadsheets, resulting in inaccuracies, delays, and difficulties in conducting root cause analysis. i-MAG OEE was developed to address this problem by automatically collecting data directly from machines in real time. So how does the i-OEE software collect data?
1. Direct Data Collection from Machine Signals
i-OEE connects directly to machinery via PLC, sensors, I/O signals, and industrial communication ports such as Ethernet, Modbus, OPC, etc. This allows the system to automatically record the complete start-stop status of the equipment, actual runtime, output quantity, and machine speed in real-time. All data is collected automatically, without manual input or human intervention, ensuring accuracy and consistency in performance measurement.
2. Real-Time Downtime Classification
When a machine stops, i-OEE automatically records the exact time of the stop and the time it restarts, classifying downtime into planned downtime (such as maintenance or setup) and unplanned downtime (due to malfunctions or machine breakdowns). During this process, operators or technical departments can directly select the cause of the machine stop on the system interface, or allow the software to record the data based on pre-set logic automatically. Thanks to clear and accurate downtime data, businesses have a solid foundation for analyzing and improving their Availability score.
3. Automatic Calculation of OEE (A-P-Q) Indicators
From the collected data, i-OEE automatically calculates:
- Availability – Equipment availability rate
- Performance – Operating performance compared to standard speed
- Quality – Product acceptance rate
All operational indicators in i-OEE are continuously updated by shift, day, week, and month, and displayed directly on the dashboard. This allows management teams to monitor production status and make decisions during operation without waiting for end-of-day reports.
4. Displaying Real-Time OEE Data on the Dashboard
After collection, operational data is processed and standardized by the i-OEE system before being visually displayed on the dashboard. Here, users can monitor OEE metrics for each machine and line, compare performance across production shifts, and quickly identify declining performance trends. This allows the factory to “see problems as they occur” and proactively take timely action.
5. Historical Data Storage & Automated Reporting
i-OEE stores all production data to:
- Retrieve downtime history
- Analyze performance trends
- Support continuous improvement (Kaizen)
In addition to displaying real-time data on the dashboard, the system can automatically compile and send OEE reports via email by day, shift, or production line. This ensures operational data is always readily available to the engineering, production, and management departments, enabling more effective collaboration in monitoring and improving performance.
6. Flexible Deployment and Easy Scalability with i-OEE
The i-OEE system is designed with a modular architecture, allowing for flexible deployment and easy scalability, suitable for various manufacturing industries such as FMCG, F&B, Packaging, as well as other industrial production sectors requiring real-time equipment performance monitoring.
- Start with 1 machine
- Expand to multiple lines, multiple factories
- Integrate with MES and ERP systems if needed
Automated data collection is the foundation for OEE to accurately reflect the actual performance of equipment. OEE is only truly valuable when data is recorded automatically, updated in real time, and detailed enough to analyze the root causes of operational problems. With i-OEE, businesses can see the true performance of their machinery without estimation, without relying on delayed reports, and without distortion due to human factors. Contact i-Soft for a demo of the i-OEE solution and an assessment of its data collection capabilities directly at your factory.
