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Most plants think their OEE is fine. The data says otherwise.

Ask three managers what last week's OEE was and you'll get three answers — all from memory. addanode puts a real OEE number on the screen: availability, performance and quality, by line, shift and product. We can do it on a brand-new line or a 25-year-old machine, usually without touching your existing PLC.

The three losses

OEE is simple. Finding the losses is the work.

PillarWhat it measuresTypical hidden loss
AvailabilityRun time vs planned timeMicro-stops and changeovers nobody logs
PerformanceActual rate vs design rateLine quietly running 10–15% slow
QualityGood units vs total unitsRework counted as "produced"

Most operators discover their true OEE is 10–20 points below what they assumed — and the biggest loss is rarely the one they were chasing.

How we measure it

Three ways onto the line — pick the least invasive that works.

Sensor-based

from ~ZAR 60K*

Output/reject counters and current clamps, no PLC contact. Live in 1–3 weeks. The fastest way to a real number.

PLC-integrated

from ~ZAR 120K*

Read existing PLC tags over Modbus/OPC-UA for richer state and fault data. No control changes.

Operator + auto

tablet add-on

Automatic timing plus a shopfloor tablet for operators to tag stop reasons — so downtime has a "why", not just a "how long".

*Indicative starting ranges per line; final scope confirmed after a site walk.

What you get in 30 days

The shortest path from "we think" to "we know".

  • A real OEE number per line, by shift and by product
  • Your top 3 downtime reasons, ranked, with minutes lost
  • Hidden speed loss against design rate
  • A shortlist of 5–15% wins that pay back the install inside a year
Production line monitored by addanode for live OEE, availability and reason-coded downtime
Frequently asked

OEE questions we answer on site.

Most OEE projects stall on one fear: that measuring the line means disturbing it. It doesn't have to.

Yes — this is the most common request. Sensor-based metering (counters and current clamps) needs no PLC contact at all, and PLC-integrated metering only reads existing tags. We don't change your control logic.
Indicatively, a single line starts around ZAR 60 000 for sensor-based visibility and ZAR 120 000+ for PLC-integrated, depending on line complexity and how many stop reasons you want captured. We confirm scope and price after a short site walk.
Sensor-based installs are usually live within 1–3 weeks, and the first 30 days of data is typically enough to identify the biggest losses.
Yes. Counters and current sensors don't care how old the machine is or whether there's a wiring diagram. That's exactly where sensor-based OEE shines.
Yes. It runs on the addaNet platform, which exposes REST/OPC-UA and SQL, so OEE and downtime data can flow into SAP, Syspro, Sage or scheduled management reports.
Related reading

Go deeper on OEE.

8 min read

Why nobody trusts your production dashboard

Manually-entered data kills boards — machine-sourced capture brings trust back.
8 min read

What does an OEE system cost?

Cost drivers, indicative ZAR bands per line, and payback.
7 min read

OEE on an old line without a new PLC

The signals a legacy machine already gives you.

Want to know your real OEE?

Tell us about one line. We'll recommend the least invasive way to put a real number on the screen — and what it costs.

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