Compiled Successfully Software Solution builds automated OEE downtime alert systems. Connect directly to machine PLCs to measure Availability, Performance, and Quality in real time. Detect machine stoppages instantly, categorize six big losses, and alert supervisors before daily targets slip.
In many manufacturing plants across India, Overall Equipment Effectiveness (OEE) is calculated retrospectively on spreadsheets hours after shifts end. Operators manually record run times and estimate downtime causes on paper sheets, resulting in inflated availability figures that hide true factory capacity.
Manual OEE calculation cannot provide real-time alerts. When availability drops to 65% at 10 AM, management only discovers the loss the following morning, making real-time intervention and scrap containment impossible.
Without direct PLC sensor integration, calculating true Availability (Run Time / Planned Time), Performance (Actual Speed / Ideal Speed), and Quality (Good Parts / Total Parts) remains subjective and contentious between production and maintenance teams.
Our platform connects directly to machine controllers to extract unadulterated facts: cycle run contacts, part counters, reject gates, and fault registers. The engine computes live OEE continuously, detects Availability drops, and dispatches automated alerts when line efficiency falls below target thresholds.
Industrial shop-floor implementation with sub-second PLC telemetry & automated ERP synchronization.
Our specialized application connects directly to machine controllers and enterprise systems without invasive code modifications, establishing deterministic real-time communication across industrial fieldbuses.
Transactional Buffer • RFC/BAPI Connectors • Protocol Translation (OPC UA, Profinet, Modbus, MQTT) • Store & Forward Caching
Physical Machine Signals → PLC Counter Tags → Edge OEE Calculation Engine → Threshold Breach Alert → Floor Andon TV & Supervisor Mobile
Replaces manual spreadsheet guesswork with tamper-proof real-time OEE, exposes hidden factory capacity, and alerts teams the moment production efficiency slips.
Built for high-speed industrial environments where downtime is measured in seconds.
Computes Availability, Performance, and Quality in real time directly from objective machine sensor signals.
Automatically categorizes losses: Equipment Failure, Setup/Adjustments, Idling/Minor Stops, Reduced Speed, Process Defects, Reduced Yield.
Dispatches mobile push alerts when line OEE drops below configurable benchmarks for more than 15 minutes.
Accurately tracks short pauses (30s–3min) that manual operator clipboards completely overlook.
Drives large factory-floor screens displaying live OEE gauges and hourly output velocity per line.
Binds OEE metrics directly to active SAP/ERP production orders for true job costing and efficiency audits.
Direct compatibility with leading global industrial automation and ERP ecosystems.
How data seamlessly flows from top-floor enterprise orders to shop-floor machine feedback.
The edge gateway reads real-time run/stop signals, high-speed piece counters, and reject pulses from the PLC.
The engine calculates Availability (Operating Time / Planned Production Time) continuously.
Performance is computed by comparing actual part cycle time against standard design takt time.
Quality is calculated directly from good pieces versus rejected scrap counts.
If overall OEE or Availability drops below the configured target (e.g., < 75%), instant alerts are dispatched.
Proven operational results across discrete and continuous processing plants.
Application: Stamping press OEE and die changeover availability tracking in Manesar and Pune.
Application: Line OEE, speed loss, and reject tracking in Baddi.
Application: Mold cycle time performance and cavity scrap analysis in Ahmedabad.
Application: Filler and labeler availability monitoring in Delhi NCR.
Why manual spreadsheets, point-to-point scripts, and isolated SCADA fall short.
| Evaluation Dimension | Traditional / Manual Methods | Compiled Successfully Platform | Operational Impact |
|---|---|---|---|
| Data Acquisition & Entry | Manual paper logbooks or end-of-shift spreadsheet entry | Sub-second automated PLC telemetry streaming & ERP posting | Zero transcription error; 100% real-time data integrity |
| Downtime & Alert Response | Local audible sirens in noisy shop floor; delays of 20-45 mins | Instant SMS, WhatsApp, and mobile push notifications with root-cause context | MTTR reduced by up to 50%; immediate intervention |
| Recipe & Parameter Download | Manual operator entry on HMI keypad; high risk of human error | Automated bidirectional recipe download from SAP order with 4-way handshake | Eliminates wrong recipe setups and expensive scrap batches |
| Architectural Resilience | Brittle point-to-point scripts without buffering; breaks on network drop | Industrial-grade Store-and-Forward with TLS 1.3 encryption | Zero telemetry loss even during enterprise network outages |
Engineered strictly according to international standards for industrial automation: ISA-95 enterprise-control integration, ISA-18.2 alarm management lifecycle, 21 CFR Part 11 electronic batch records, and TLS 1.3 / mTLS outbound cryptographic security. Built-in Store-and-Forward guarantees zero telemetry loss during network drops.
Connect a single production line in under 3 weeks with zero line disruption.
Request Pilot DemoTurnkey industrial automation and smart factory integration deployments across major industrial corridors in India.
Technical and operational answers for plant managers and automation engineers.
Discuss your PLC, SCADA, machine monitoring, IIoT or Industry 4.0 requirement with our industrial automation team. See how PLC events, SCADA alarms, machine downtime and industrial conditions can be monitored through web dashboards and mobile alerts.
