58% → 71%
OEE Improvement
94%
Downtime Classification
22 min
Changeover Time Saved
15
Machines Connected
The Challenge
The plant ran 10 progressive die stamping presses and 5 spot weld stations across three shifts with no real-time downtime capture. Shift leads logged stoppages on paper at the end of each shift — often incomplete and always too late to act on. OEE was calculated in Excel the following morning. Management had no visibility into which machines were the biggest contributors to lost production, and chronic delivery shortfalls to their OEM customer were becoming a contractual risk.
The Solution
Connected all 10 stamping presses to their respective PLCs — 3 Omron CP1E-S and 5 Omron CP2E-S units via Omron Host Link (C-mode), and 2 Mitsubishi FX1S series PLCs via Mitsubishi MC protocol — and integrated the 5 spot weld stations through their native weld controller interfaces to capture cycle counts, weld quality flags, and fault codes. Deployed OEE Monitoring and Downtime Management on MACHHUB. Operators classify downtime reasons directly on touchscreen panels at each machine within 60 seconds of a stoppage. Supervisor dashboards on shop floor TVs and mobile give live line status, and shift-end reports are generated automatically.
The Result
Downtime classification accuracy improved from an estimated 40% (manually guessed post-shift) to 94% (system-captured in real time). OEE rose from 58% to 71% over five months. Analysis of the top downtime causes enabled a changeover improvement project — average die changeover time was reduced by 22 minutes, recovering approximately 3.5 hours of productive capacity per line per week.
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