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Kathy Barthelt

Tip of the Week: 10 Ways to Succeed at an OEE Project Where 90% Fail

  1. Collect the requirements. Learn from everyone with the intent of developing a phased approach to implementing on your shop floor with OEE being Phase 1. 
  2. Create your list. Capture all of required functions, taking into account what the “output” of the system will be. What does the plant manager need to see in real-time? What KPI’s does each line need displayed in real-time? What reports are required?
  3. Insist Upon Real-time. In the moment data for the right OEE is the right approach. If it’s possible, collect the data automatically. Remember that real-time feedback to line operators results in an automatic increase in OEE.
  4. Evaluate your lines. Focus where production counts can be monitored automatically. If the data is in your PLC’s, can you get it out? OPC communication is the right way to go here. If not, the approach is to install a new dedicated PLC with sensors installed on each line.
  5. Find Your Data Points. If automatic production monitoring is not applicable, what will be your collection points and how will you collect the data?
  6. Calculate the Load. Determine how to load the “job” you’re reporting on into the OEE system. This will typically be the order/operation or the product from the ERP.
  7. Recognize Great Data. Do not accept “manual collection of data” as a viable approach because it produces false results and is labor-intensive.
  8. Be Tough. Evaluate systems based on OEE specificity to start and expandability to future phase functions as determined by your requirements. Plan to justify the OEE purchase on its own merits.
  9. Go Easy. Make sure the system is easy to implement. Software installation and configuration should take no more than 2 weeks.
  10. Be Simple. Put together a detailed but simple project plan indicating who will do what, how long it will take, and how you will monitor progress.
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Industry Insight: Why ERP Data Stays Siloed, and What to Do About It

Most manufacturers don't have a data problem. They have a connection problem.

Production data lives in one system. Sales and customer data lives in another. Finance runs somewhere else entirely. Each system does its job well on its own, but without a way to connect them, the organization never gets the full picture, and neither do the people trying to run the business.

Why This Happens
ERP systems are often the core of a manufacturer's operations, but they rarely operate alone. Over time, businesses add third-party software for CRM, e-commerce, warehouse management, EDI, and more. Each addition solves an immediate need, but without integration, it also creates another silo.

The result is familiar across manufacturing: teams end up manually re-entering data between systems, waiting on reports that should be immediate, and making decisions without visibility into what's happening elsewhere in the business.

Integration vs. Enhancement
There are two ways to close this gap, and they solve different problems:

  1. ERP Integration connects your ERP to the third-party software you use every day, creating a single source of data instead of several disconnected ones. Whether it's a one-way, two-way, or complex systems integration, the goal is the same: eliminate errors, reduce manual entry, and give everyone access to the same real-time information.
  2. ERP Enhancement goes a step further, creating new functionality or modifying existing functionality within the ERP itself, so the system matches how your business actually operates rather than forcing your business to adapt to the system's limitations. Done right, enhancements use parameter-co

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