+9.2pp OEE across four plants, £3.1m annual uplift.
A UK discrete manufacturer was running OEE in the mid-60s across four plants. A real-time IoT and analytics platform — with closed-loop shift optimisation — lifted OEE by 9.2 points in ten months.
From dashboards to decisions.
Shift reports landed hours after shift end; micro-stoppages were attributed after the fact, if at all. We wired OPC-UA telemetry into a streaming analytics layer, added edge anomaly detection, and closed the loop into shift-level operating rhythm.
Approach.
Pilot plant (weeks 1–6)
One plant, one line, end-to-end loop proven with measurable lift.
OT-IT bridge
OPC-UA via safe read-only gateway; change-control respected.
Edge anomaly detection
Per-line models detecting micro-stoppages and speed loss in real time.
Closed-loop rhythm
Shift-handover dashboards, team-board automation, variance attribution.
Plant-by-plant rollout
Months 4–10 — templated, standardised, measurable.