Real-Time OEE Software
for Modern Factories
Stop running your shifts on retrospective data. Automate Overall Equipment Effectiveness (OEE) tracking, pinpoint the Six Big Losses instantly, and drive continuous improvement — with zero PLC code modifications.
Built for Mixed-Age Factory Fleets
Traditional OEE tools require expensive PLC logic rewrites. AdaptNXT uses a non-invasive telemetry stack.
Non-Invasive Retrofits
Read cycle counts and machine states using external sensors, CT clamps, or read-only Modbus connections. We shield your core PLC programs from any modifications — no production halts, no warranty risks.
Six Big Losses Breakdown
Don't just settle for an OEE percentage. Our software automatically classifies downtime into setup overruns, micro-stops, cycle speed loss, and reject counts — so you can prioritize the right fix.
Financial Loss Leakage
Convert performance percentages into money. Show the CFO precisely what hourly bottlenecks cost in annual revenue — and prioritize maintenance spend where it delivers the highest OEE ROI.
Real-Time OEE Tracking
Calculate OEE = Availability × Performance × Quality automatically from live machine data. Detect micro-stops and speed losses the moment they happen — not hours later in a spreadsheet review.
Predictive Alerts & Anomaly Detection
Set threshold-based OEE alerts or enable ML anomaly detection to catch performance degradation before it collapses your score. Receive instant notifications via SMS, email, or webhook integrations.
ERP & MES Integration
Sync OEE scores, downtime reasons, and part count aggregates directly with SAP, Oracle, or your existing MES via our secure REST API and webhook event streams. No middleware required.
Our 8-Week Fixed-Price OEE Pilot
Mitigate deployment risk. We connect 3 to 8 machines and establish verified OEE baselines before you commit to scaling across the plant.
- Non-invasive sensor installation with zero production stoppage.
- Verified OEE baseline with top 3 downtime loss categories identified.
- Quantified ROI business case delivered by Week 8.
8-Week Pilot Structure
Weeks 1–2: Installation
Mount edge gateways, deploy non-invasive sensors, configure live dashboards per machine.
Weeks 3–4: Baseline Audit
Establish raw OEE baselines. Identify top 3 downtime categories dragging down shifts.
Weeks 5–8: ROI Verification
Kaizen focus on bottlenecks, compare baseline vs. improvement, quantify annual ROI.
Real Results from the Shop Floor
OEE Lifted from 58% to 78%+
We retrofitted 40 legacy CNC milling machines with non-invasive vibration, current, and temperature sensors. By automating OEE tracking and deploying predictive anomaly models, the client eliminated major spindle failures and reduced unplanned downtime by 40%.
Objections Handled
Everything you need to know about evaluating and deploying AdaptNXT's OEE software.
Yes. We specialize in brownfield setups. For legacy CNCs, presses, or assembly equipment without network ports, we deploy external non-invasive sensors (like current clamps and photo-electric count triggers) connected to our optically-isolated edge gateways. Your machines are monitored safely with zero risk of electrical loops or warranty voids.
No. Our edge gateway includes local SPI Flash storage buffering. If your factory Wi-Fi or cellular network drops, all machine cycles and telemetry timestamps are cached locally and synchronized with the cloud once connection returns. No data points are lost.
Yes. Our cloud platform exposes secure REST APIs and real-time webhook integrations. Downtime reasons, part count aggregates, and computed OEE scores can be synchronized directly with your ERP, MES, or local database systems.
Our 8-week pilot is structured for rapid deployment. We install gateways on 3–8 bottleneck machines in Week 1, establish OEE baselines by Week 3, identify top downtime losses in Week 5, configure real-time warning alerts by Week 7, and present the quantified business case by Week 8.
Industry benchmarks consider 85% OEE as world-class. Most manufacturing plants start between 40%–60% when they first begin tracking OEE accurately. A realistic first-year goal is to move from your baseline to 70%+ by addressing the top two or three loss categories identified by the system.
Drive Shop Floor Efficiency with Real-Time OEE
Get accurate, real-time OEE metrics and identify hidden capacity on your bottleneck lines today.