Manufacturing & Advanced Industrials · Operations & Asset Management
Plant Productivity & OEE Diagnostic
Find the capacity already in your plant before you invest in new production lines
Discuss this serviceWhat it is
Plant Productivity & OEE Diagnostic
A Plant Productivity Diagnostic is a focused study of how effectively your machines, lines, and people turn available time into good output. Using Overall Equipment Effectiveness (OEE) and loss-tree analysis, we identify bottlenecks and estimate the financial value of recovering lost output.
- Typical duration
- 3 to 5 weeks
The business problem
Why clients need this
Plants often request expansion capex while existing lines run well below their capability. The losses are spread across minor stops, slow running, long changeovers, and rework, so no single one looks large.
- 01
Leadership does not have an objective baseline of true capacity by line, shift, and product.
- 02
Downtime and rejection data sits in operator logbooks without structured root-cause analysis.
- 03
New equipment is budgeted when the real constraint is maintenance, changeover time, or scheduling.
Our approach
How we deliver it
- 1
Data Collection & Sensors
Extracting machine data, PLC logs, and maintenance records, and adding temporary non-invasive sensors where data is missing.
- 2
Shop-Floor Observation
Our industrial engineers observe production across shifts, covering changeovers, material staging, and bottleneck starvation.
- 3
OEE Loss-Tree Analysis
Breaking losses down into Availability (breakdowns, setups), Performance (speed loss, minor stops), and Quality (rework, scrap).
- 4
Prioritised Improvement Roadmap
Sizing each improvement by financial value and effort, with 90-day milestones for the first wave.
Data & AI
How technology strengthens this service
Analysing machine time-series data reveals short stops and speed losses that are rarely recorded in shift logs, giving a more accurate picture of where time is actually lost.
How we use AI across our workTypical deliverables
What you receive
- Plant OEE Baseline by line and machine
- Loss Tree with the estimated financial impact of each loss category
- Root-Cause Analysis of the top 5 bottleneck operations
- Prioritised 90-Day Quick Wins & 12-Month Improvement Roadmap
Outcomes
What changes for you
- A verified capacity baseline that leadership and operations both accept
- A clear view of whether planned expansion capex is needed, or can be deferred
- Daily performance routines and visual management that keep the focus on losses
Who it is for
- Automotive & precision component manufacturers
- Chemical & process industry operators
- Pharmaceutical & FMCG packaging plants
- Heavy engineering & fabrication shops
FAQs
Common questions
Do we need an MES or digital factory software for this diagnostic?+
No. We work with whatever data you have and install temporary wireless sensors on key machines if needed.
Will the diagnostic disrupt production?+
No. Observation, data collection, and sensor logging run alongside normal production.
How quickly do recommendations turn into results?+
Quick wins such as setup reduction and bottleneck balancing are designed to show measurable gains within the first 30 to 60 days of implementation.
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Discuss plant productivity & oee diagnostic with our team
Tell us about your site, plant or network. A senior consultant will reply within two business days.