{"id":4429,"date":"2022-08-30T08:58:47","date_gmt":"2022-08-30T08:58:47","guid":{"rendered":"https:\/\/sensor-online.se\/?p=4429"},"modified":"2026-03-29T10:40:17","modified_gmt":"2026-03-29T10:40:17","slug":"oee-monitoring-sensor-online-production-kpi","status":"publish","type":"post","link":"https:\/\/sensor-online.se\/sv\/oee-monitoring-sensor-online-production-kpi\/","title":{"rendered":"OEE Monitoring with Sensor-Online \u2013 Real-Time Production KPIs"},"content":{"rendered":"<h2>OEE: The Standard KPI for Manufacturing Productivity<\/h2>\n<p>OEE \u2013 Overall Equipment Effectiveness \u2013 combines three factors into a single number that tells you how efficiently a machine or production line is running: availability (is it running when it should be?), performance (is it running at rated speed?) and quality (is it producing good parts?). A world-class OEE is generally considered to be 85% or above. Most facilities starting IoT monitoring find their actual OEE is significantly below what they assumed.<\/p>\n<h2>How Sensor-Online Calculates OEE in Real Time<\/h2>\n<p>Sensor-Online collects the raw signals needed for OEE from machine sensors, counters and production line interfaces \u2014 then calculates the three components continuously using the built-in JavaScript engine:<\/p>\n<ul>\n<li><strong>Availability<\/strong> \u2014 calculated from machine run\/stop signals, planned production time and recorded downtime events<\/li>\n<li><strong>Prestanda<\/strong> \u2014 derived from production count sensors or pulse counters compared against the ideal cycle time<\/li>\n<li><strong>Quality<\/strong> \u2014 calculated from reject counters or manual quality inputs recorded via the API<\/li>\n<\/ul>\n<p>The resulting OEE value is displayed as a live KPI widget on a Sensor-Online dashboard, updated every time new data arrives from the machine.<\/p>\n<h2>Connecting Machines to Sensor-Online for OEE<\/h2>\n<p>Machines can be connected using several approaches depending on existing hardware:<\/p>\n<ul>\n<li><strong>LoRaWAN I\/O sensors<\/strong> \u2014 digital input sensors that read run\/stop and count signals from the machine\u2019s control panel or proximity sensors, no PLC modification required<\/li>\n<li><strong>Modbus TCP\/RTU<\/strong> \u2014 read directly from the machine\u2019s PLC if Modbus communication is available, giving access to cycle counts, fault codes and speed data<\/li>\n<li><strong>OPC-UA<\/strong> \u2014 for modern machines with OPC-UA servers, providing standardised access to all process variables<\/li>\n<li><strong>Milesight UC300<\/strong> \u2014 a versatile IoT controller with analog, digital and serial interfaces that can be installed next to almost any machine without PLC access<\/li>\n<\/ul>\n<h2>OEE Dashboard and Alerting<\/h2>\n<p>A well-designed OEE dashboard in Sensor-Online shows current OEE alongside the individual Availability, Performance and Quality breakdowns, plus a Pareto chart of the top downtime reasons. This makes it immediately clear what to address first to improve overall equipment effectiveness.<\/p>\n<p>Sensor-Online\u2019s alarm engine triggers notifications when OEE drops below a configurable threshold \u2014 for example, sending an SMS to the shift supervisor when OEE falls below 70% during a production shift.<\/p>\n<h2>From Single Machine to Factory-Wide OEE<\/h2>\n<p>Starting with OEE monitoring on one critical machine is the most common approach. Once the data collection and calculation logic is established in Sensor-Online, the same configuration can be replicated across an entire factory floor by adding more sensors to the same gateway and duplicating the JavaScript calculation scripts.<\/p>\n<h2>FAQ: OEE Monitoring with IoT<\/h2>\n<h3>Do I need to modify my PLC to connect to Sensor-Online?<\/h3>\n<p>Not necessarily. LoRaWAN I\/O sensors can read run\/stop and count signals from a machine\u2019s electrical panel without any PLC modification. Modbus and OPC-UA connections require that the PLC has an available communication port, but no changes to the control program are needed.<\/p>\n<h3>How accurate is IoT-based OEE compared to MES systems?<\/h3>\n<p>For machines where signal sources are well-defined (clear run\/stop and count signals), IoT-based OEE calculation in Sensor-Online matches MES accuracy. For highly complex multi-step processes, a full MES may offer more detailed tracking, but the setup cost is significantly higher.<\/p>\n<h3>Can Sensor-Online push OEE data to our ERP or production reporting system?<\/h3>\n<p>Yes. Via the REST API, MQTT or a Node-RED integration, OEE values and underlying signals can be forwarded to any ERP, MES or BI system in real time.<\/p>\n<p>Learn more about <a href=\"https:\/\/sensor-online.se\/sv\/iot-solutions-for-industrial-control\/\">industrial IoT solutions<\/a> or explore <a href=\"https:\/\/sensor-online.se\/sv\/produkter\/\">Sensor-Online\u2019s platform capabilities<\/a>.<\/p>","protected":false},"excerpt":{"rendered":"<p>OEE: The Standard KPI for Manufacturing Productivity OEE \u2013 Overall Equipment Effectiveness \u2013 combines three factors into a single number that tells you how efficiently a machine or production line is running: availability (is it running when it should be?), performance (is it running at rated speed?) and quality (is it producing good parts?). A&hellip;<\/p>","protected":false},"author":1,"featured_media":4430,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_feature_clip_id":0,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_post_was_ever_published":false},"categories":[211],"tags":[47,53,50,52],"class_list":["post-4429","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news-2026","tag-iiot","tag-industry40","tag-manufactoring","tag-tak","category-211","description-off"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.1 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>OEE Monitoring with Sensor-Online \u2013 Real-Time Production KPIs - Sensor-Online<\/title>\n<meta name=\"description\" content=\"Monitor OEE (Overall Equipment Effectiveness) in real time with Sensor-Online. 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