Most manufacturers know their OEE is lower than it should be. Few know exactly why — because they are calculating it from shift logs, manual counts, and production reports compiled hours after the shift ends. By the time the number is visible, the losses that drove it have already happened and the shift that could have responded to them has gone home. Real-time OEE software changes the response window from hours to minutes. Start Oxmaint free and connect your first production line in under a day.
Real-Time OEE Dashboard
See Every Production Loss as It Happens
Oxmaint pulls live data from your PLCs, sensors, and production counters to calculate OEE continuously — availability, performance, and quality in real time, on every line, every shift. No manual data entry. No end-of-shift reports. No surprises at month-end.
Line 3 — Hot Strip Mill
Live
83%
91%
96%
OEEAvailabilityPerformance
83%
World-class OEE target — most facilities run at 58–68% without real-time visibility
$0
Cost to start Oxmaint OEE monitoring — free plan, no credit card, first data in under a day
15 min
Average time from a production loss event to corrective action with real-time OEE alerts
20 pts
Average OEE improvement within 12 months of deploying real-time monitoring and structured loss elimination
OEE's value is not the headline percentage — it is the loss decomposition that tells you exactly which category of inefficiency is consuming the most production time. Oxmaint maps every downtime event, speed reduction, and quality rejection to its loss category automatically, generating a live ranked list of your highest-value improvement opportunities. Book a demo to see the Six Losses dashboard configured for your production lines.
Availability Loss
01
Planned Downtime
Scheduled maintenance windows, shift changes, planned changeovers. These stops are unavoidable but must be minimised and tracked. Oxmaint links planned downtime events directly to PM work orders — every planned stop has an owner, a start time, a target duration, and an actual duration. Chronic overrun is flagged automatically.
Oxmaint action: Compare planned vs. actual duration per stop type — identify which maintenance tasks consistently overrun and target them for job pack preparation improvement.
Availability Loss
02
Unplanned Breakdowns
Equipment failures that stop production without advance warning. The highest-cost loss category in most manufacturing operations — emergency repair costs 3–5× planned maintenance, plus the full production cost of unplanned downtime. Real-time OEE feeds directly into MTBF tracking, showing which assets are driving the most breakdown availability loss.
Oxmaint action: Breakdown events auto-generate corrective work orders linked to the OEE loss record — full traceability from production loss to root cause to resolution.
Performance Loss
03
Reduced Speed
Equipment running below rated speed due to minor adjustments, quality concerns, or operator caution. Often invisible without direct PLC data integration — manual production logs frequently show "running" for periods when speed is actually 30–40% below rated. Oxmaint's PLC integration captures actual speed vs. rated speed continuously.
Oxmaint action: Speed loss alerts trigger investigation work orders when actual speed drops below configured threshold for more than a set duration.
Performance Loss
04
Minor Stops and Idling
Short stops under 5–10 minutes that are individually minor but collectively significant. Jams, sensor faults, brief blockages, operator adjustments. These events rarely appear in shift logs but are captured in real time through PLC cycle time monitoring. In many facilities, minor stops represent 8–15% of total available time — more than all planned downtime combined.
Oxmaint action: Pareto analysis of minor stop frequency by asset and time of shift — identifies whether causes are mechanical, process, or operator-related.
Quality Loss
05
Startup and Yield Losses
Scrap and rework produced during startup after a stop or changeover — the equipment is running but producing off-spec product. Startup loss is often directly correlated with maintenance quality: an equipment setup performed to documented standard produces less startup scrap than one improvised by a different technician on a different shift.
Oxmaint action: Links startup quality data to the maintenance work order that preceded the startup — identifying which maintenance tasks correlate with high startup scrap rates.
Quality Loss
06
Process Defects
Defects produced during steady-state production — equipment running at speed but producing non-conforming product. In many processes, the root cause is equipment condition: worn tooling, drifted calibration, or degraded process parameters that produce quality variation before they produce a detectable mechanical failure. Tracking quality loss against equipment condition data reveals the connection.
Oxmaint action: Quality rejection events linked to asset condition records — identifies equipment deterioration driving quality losses before it becomes a breakdown.
Oxmaint maps every production loss to its Six Losses category automatically. Your OEE dashboard shows the ranked loss list — so your team works on the highest-value problem, not the most visible one.
Oxmaint's OEE engine collects data from three sources simultaneously: PLC and sensor integration for availability and speed data, production counter feeds for throughput, and quality system integration or manual entry for first-pass yield. The four steps below show how raw machine data becomes a real-time OEE number visible to operators, maintenance teams, and production managers on the same shared dashboard. Sign in to Oxmaint to connect your first production line.
1
Connect Data Sources
Oxmaint connects to PLCs via OPC-UA or MQTT, historian systems via REST API, and production counters directly or through your MES. Setup time for a standard production line: 2–4 hours with your automation team. No custom development required.
2
Calculate OEE Continuously
Oxmaint calculates Availability, Performance, and Quality metrics from live data streams. OEE refreshes every 60 seconds. Each downtime event, speed deviation, and quality rejection is automatically classified to its Six Losses category as it occurs.
3
Alert and Assign
When OEE drops below your configured threshold, or when a specific loss category exceeds its limit, Oxmaint sends an alert to the responsible supervisor and optionally creates a work order automatically — keeping response time under 15 minutes from event to assigned action.
4
Analyse and Improve
Oxmaint's OEE analytics show loss trends by shift, asset, operator team, and product type. Pareto charts identify the three loss categories consuming the most production time — focusing improvement effort where it generates the highest return rather than where the last problem occurred.
Without Real-Time OEE
OEE calculated from shift logs — available 4–12 hours after the shift ends
Minor stops and speed losses are invisible — they never appear in manual logs
Loss categories estimated after the fact — root cause investigation is guesswork
Month-end OEE report surprises management — problems are already embedded in results
Maintenance team hears about production losses days after they occur
With Oxmaint Real-Time OEE
OEE visible live on the dashboard — refreshed every 60 seconds during production
Every minor stop captured via PLC — Pareto shows which asset causes the most events
Loss category assigned automatically at event — root cause investigation is data-driven
Supervisors see OEE drop in real time and can act before the shift loss compounds
Maintenance receives work order within 15 minutes of a breakdown — response starts immediately
+18 pts
OEE improvement at a European automotive stamping plant within 10 months of deploying Oxmaint real-time OEE — from 61% to 79%
62%
Reduction in minor stop events at a packaging line after Oxmaint's Pareto analysis identified one jam point on a single conveyor transfer station as the source of 38% of all minor stops
4.2×
Return on Oxmaint investment in year one at a food and beverage facility — driven entirely by availability improvement from reduced unplanned breakdown time on two filling lines
Frequently Asked Questions
What PLC and automation systems does Oxmaint's OEE integration support?
Oxmaint connects to production data through OPC-UA, MQTT, and REST API — which covers the vast majority of modern industrial automation platforms including Siemens S7/TIA Portal, Rockwell/Allen-Bradley, Schneider Electric, Mitsubishi, and Beckhoff. For legacy PLCs without native OPC-UA, Oxmaint integrates through existing SCADA or historian systems (OSIsoft PI, Wonderware, Ignition) that already aggregate the PLC data. In most facilities, OEE data is flowing within 4–8 hours of starting the integration setup. Start free and our integration team will scope your specific automation environment in the onboarding session.
Can we start tracking OEE before we have PLC integration — using manual data entry?
Yes. Oxmaint supports both automated data feeds and structured manual data entry for facilities where PLC integration is a future phase. Operators enter downtime events with start time, end time, and cause code via the mobile app — Oxmaint calculates availability, prompts for production count and quality data, and generates the OEE figure. Manual data entry captures approximately 85–90% of the value of automated integration for most facilities, because the primary OEE loss categories (planned downtime, major breakdowns, and quality rejections) are reliably captured manually. Minor stops and speed losses require PLC integration to capture accurately. Book a demo to see both modes configured side by side.
How does Oxmaint's OEE connect to its maintenance work order and PM scheduling functions?
This integration is the core differentiator between a standalone OEE tool and an OEE-connected maintenance platform. In Oxmaint, every downtime event on the OEE dashboard is directly linked to either an existing PM work order (planned downtime) or a newly created corrective work order (breakdown). The maintenance team sees the production impact cost calculated on the work order — not just the repair task. PM compliance data from the maintenance module feeds directly into the OEE availability trend — showing the correlation between PM completion rates and equipment availability over time. This closed loop between OEE loss and maintenance action is what converts OEE data from a measurement into an improvement driver.
Turn Your OEE Number Into an OEE Improvement Program
Real-time OEE visibility without a connected maintenance system is just a faster way to watch your losses. Oxmaint connects every OEE loss directly to a maintenance work order — turning measurement into action, and action into results.
