OEE Downtime
Smarter performance tracking for a more productive operation.
Intro to OEE Downtime
The Sepasoft OEE Downtime Module helps manufacturers improve equipment effectiveness across lines, plants, and enterprises by reducing operating costs, increasing throughput, and driving higher profitability.
Key Capabilities:
- Real-Time OEE and Downtime Tracking
- Root-Cause Downtime Detection
- Production Scheduling
- Live and Historical Analysis
- Automated Data Collection
- Multi-Site and Enterprise Scalability
- Seamless Integration
Real-Time OEE and Downtime Tracking
Get a live view of equipment performance across every line and shift. The OEE Downtime Module continuously collects production counts, cycle times, and downtime events to show how each process is performing right now. The resulting data provides a clear foundation for configurable KPIs that highlight performance trends and production losses.
Root-Cause Downtime Detection
Record downtime automatically and pinpoint the reasons behind it. Built-in detection methods analyze machine states and flow conditions to identify the true cause of each stop, even within complex multi-cell or parallel line configurations. Downtime reasons can be grouped, filtered, and analyzed to help teams make targeted improvements that reduce unplanned interruptions.
Production Scheduling
Track schedules in real time and measure progress against plan. The OEE Downtime Module displays scheduled work orders and routine events such as maintenance alongside current equipment status. Work orders can be imported from ERP or created locally, giving operators and supervisors clear visibility into upcoming production and enabling faster communication with quality, maintenance, and warehouse teams.
Changeover and Equipment Modes
Manage changeovers efficiently and track equipment modes such as production, maintenance, idle, or R&D. Each mode and state can be configured to reflect your actual operations, ensuring accurate utilization data. Planned downtime is automatically separated from unplanned stops, providing precise OEE calculations and consistent reporting for audits or compliance reviews.
Live and Historical Analysis
Analyze performance across any time period, from the current shift to quarterly results. The analysis engine calculates OEE, cycle times, and performance losses using a standardized approach across all sites. Users can create custom analyses, compare date ranges, and save or share their results. Live analyses refresh continuously to keep everyone informed with the latest data.
Automated Data Collection
Capture performance data automatically to maintain a real-time view of production efficiency. Automated data collection delivers timely and reliable information that supports accurate KPI calculations and faster response to issues. For processes that cannot be fully automated, hybrid and manual data collection options ensure flexibility and completeness across every production environment.
Multi-Site and Enterprise Scalability
Scale from one site to an entire enterprise without restructuring your system. Multi-site synchronization allows global teams to compare performance and share standardized downtime reasons, schedules, and KPIs while still maintaining local flexibility. This unified approach helps larger organizations drive consistent improvement across multiple facilities.
Seamless Integration and Data Reliability
Integrate easily with ERP and IIoT systems to ensure consistent data flow across operations. The module’s store-and-forward design guarantees data reliability during network interruptions. Information can be exported, imported, or analyzed externally, while detailed audit logs maintain accuracy and compliance with industry standards.
Built on the Ignition® platform by Inductive Automation, the OEE Downtime Module takes advantage of Ignition’s modern architecture, flexible scripting, and unlimited licensing model. This native integration allows OEE data to flow directly within your Ignition projects, providing a single, connected environment for MES, SCADA, and enterprise systems.
OEE Modules Comparison Matrix
Quickly identify and focus your efforts on the top downtime reasons affecting your operating efficiency.
| Feature | Benefit | Standard | Enterprise |
| Downtime Analysis | Accurately determine the root cause for loss of production with advanced downtime detection algorithms. |  | |
| Easy Ad-Hoc Analysis | Pinpoint production inefficiencies with customizable ad-hoc analysis, allowing users to select unique combinations of data values, filters, groupings, and orders. | | |
| Post-Run Corrections | Keep KPIs, analysis results, and historical data accurate with the ability to adjust previously collected production data. | | |
| Chart & Table Drill Down | Achieve a deeper understanding of OEE analysis with chart and table drill-down functionality. | | |
| Historical Analysis | Identify downtime trends and target areas for improvement by retaining and analyzing unlimited amounts of past production data. | | |
| Record Custom Data Items | Evaluate how non-OEE factors (e.g. vendor, tooling) are affecting efficiency by incorporating custom data items into your analysis. | | |
| Automated Production Reports | Reliably communicate OEE results across the organization by integrating with Ignition Reporting to automatically generate and send reports via email or other methods. | | |
| Multiple Site Analysis and Reporting | Monitor production efficiency across all operations of your global enterprise by comparing OEE and production results across sites and production areas. | |
Drive continuous improvement by responding to production issues in real-time.
| Feature | Benefit | Standard | Enterprise |
| Real-Time OEE Scores | Respond to production issues as they happen with live notifications and visual feedback showing overall OEE, availability, performance, and quality scores. | | |
| Dynamic Dashboards | Share meaningful information using real-time custom dashboards tailored to the needs of your company. | | |
| Real-Time Equipment Data Collection | Minimize error and reduce manual input by capturing equipment data automatically, freeing up operators to focus on their primary task of producing product. | | |
| Equipment Timing Chart | Determine the root cause of downtime events and optimize material flow by visualizing interactions between line equipment. | | |
| Live KPIs | Configure custom Key Performance Indicators (KPIs) that will best help your organization improve production efficiency. | | |
Easily adapt to organizational growth with a unified MES solution that supports change over time. Sepasoft MES expands from the edge-of-network up to a global enterprise with no rework or loss of data.
| Feature | Benefit | Standard | Enterprise |
| MES Server Health Monitoring | Detect and resolve system issues before they cause loss of production with out-of-the-box health monitoring tools. | | |
| IIoT/MQTT Functionality | Prevent the loss of historical data, optimize network bandwidth, and improve security by capitalizing on IIoT, with built-in MQTT and OPC/UA support. | | |
| Unlimited Lines per Site Licensing | Scale your MES system as your organization grows without significant licensing costs or hidden fees. Unlike alternatives, a Sepasoft site license includes unlimited lines and machines. Users, screens, reports, and field device connections are unlimited within a site license. | | |
| Multiple Site Production Data Synchronization | Improve visibility and reliability throughout the enterprise by easily sharing schedules, production results, and more across multiple sites and servers. With out-of-the-box functionality, integration labor and custom coding are significantly reduced. | | |
| Multiple Site Configuration Synchronization | Simplify the configuration process with automatic synchronization across multiple sites and servers. Minimize duplicate entry, misconfigurations, and other entry mistakes without custom coding. | |
Customize system configuration to meet the unique requirements of your organization.
| Feature | Benefit | Standard | Enterprise |
| Automatic, Manual, or Hybrid Data Collection | Reduce operator workload with automatic data collection, with the option to collect valuable details manually. With the flexibility to collect data automatically, manually, or through a hybrid process, all relevant OEE information is captured. | | |
| Data Export/Import Capability | Enjoy the freedom to use production data however you choose. Optionally, export and import data with external systems for further analysis or configuration. | | |
| Material Management | Keep your key performance indicators (KPIs) accurate by configuring unique rates and settings for each material-equipment combination. | | |
| Manage Documents & Artifacts | Ensure the correct versions of materials safety data sheets (MSDS), work instructions, travelers, and more are available when needed. Attach additional data files (e.g. images, PDFs, etc.) to schedules, work orders, materials, equipment, and more. | | |
| Configurable Equipment Modes | Track asset utilization by configuring user-defined equipment modes that are most meaningful to your manufacturing process. User-definable modes can be anything but typically include changeover, set up, R&D, production, maintenance, and idle. | | |
| Equipment Manager Component | Easily configure your equipment hierarchy in an intuitive representation of your plant floor. Define state, mode, and other settings unique by site, area, line, machine, and more. | | |
| Detailed Changelog | Automatically record all changes made to any MES configuration to help you meet the challenges of regulatory compliance. Quickly zero in on significant changes with access to a complete audit trail of the location, date, type of change, responsible person, and more. | | |
| Multi-Database Vendor Support | Simplify implementation by selecting the database vendor that best fits into your existing IT standards. | | |
| ISA-95 Alignment | Built on industry standards for equipment models and data structures, ensuring consistency and easy integration across MES and enterprise systems. | | |
Achieve production goals by tracking progress and monitoring production conditions using live visual feedback.
| Feature | Benefit | Standard | Enterprise |
| Running Changeover | Accurately track production counts and other key data when running multiple products on a line. Leverage built-in OEE algorithms that support running changeovers with two or more products running on a line simultaneously. | | |
| Flexible Shift Configuration | Accurately predict production outcomes that match your shift schedules with flexible shift configuration, including rotating shifts and holidays. | | |
| Live Plant Floor Scheduling | Determine whether you’re on track to meet production targets at any given moment. Plant floor scheduling is automatically updated and forecasted based on live production conditions, providing you constant feedback on the status of operations. | | |
| Scheduling Analysis | Analyze past production runs to identify trends and carry forward successful practices to future operations and scheduling. | | |
| Work Order Management | Fulfill production targets by tracking the real-time status of work orders, including units scheduled, produced, and remaining. Work orders spanning multiple runs or lines can be viewed in aggregate, providing the ability to review the work order as a whole. | | |
Transition from isolated systems and data silos to a coordinated, full-featured MES. With Sepasoft’s modular design, business systems of different functional areas can work together in harmony for greater insight.
| Feature | Benefit | Standard | Enterprise |
| Automatic Machine Settings Management | Manage machine settings to prevent quality issues and downtime. Identify deviations as they happen and quickly resolve critical issues with role-based management. To learn more, visit our Machine Settings Management (formerly Recipe & Changeover) product page. | | |
| Document Management | Securely and easily manage production-related documents that are critical to safety, quality, and overall production efficiency. Build and distribute documents that operators can fill out and save with MES data for the historical record. To learn more, visit our Document Management product page. | | |
| Synchronization to ERP Systems | Connect to your ERP or higher-level business system without custom development or the burden of maintaining high volumes of the script over time. Complicated scripts are replaced by a user-friendly visual interface to sequence communication and map data between systems. To learn more about ERP synchronization, visit our Interface for SAP ERP product page. To learn more about business systems connectivity, visit our Sepasoft Business Connector product page. | | |
| Integrated Quality Tracking | Minimize waste and rework by catching quality issues early in the production process. Identify out-of-control variations with automatic alerts to resolve them before they become bigger (and more costly) problems. To learn more, visit our SPC product page. | | |
| Integrated Traceability | Rapidly recall material genealogy from raw materials to finished goods, including real-time WIP inventory on the plant floor. To learn more, visit our Track & Trace product page. | | |
| Compatible with Ignition | Save hours of customization by managing MES, SCADA, HMI, and more on a single platform with a unified operator interface and design tools. To learn more about the Ignition Platform, visit Inductive Automation’s Ignition Platform product page. | | |
Excited to learn more? Reach out to us and schedule your live demo today!