Overall Equipment Effectiveness and Operational Performance

Objectively measure manufacturing productivity, identify improvement opportunities, and increase profitability with OEE software. Transform operational data into actionable intelligence to improve availability, performance, and quality, reduce downtime, and drive continuous improvement across your enterprise.

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The Challenge: Limited Visibility into OEE and Production Performance

Manufacturing organizations often struggle to understand the true efficiency of their production processes and accurately measure overall equipment effectiveness (OEE). Without clear visibility into availability losses, performance bottlenecks, quality issues, and downtime events, teams lack the insights needed to prioritize improvements and maximize productivity. Traditional manual tracking methods are time-consuming, inconsistent, and fail to deliver real-time intelligence. When organizations cannot accurately measure the gap between potential output and actual production, critical opportunities to reduce costs, increase throughput, and improve competitiveness are lost.

Common Challenges

  • Lack of real-time visibility into OEE, production line performance, and equipment utilization
  • Inability to distinguish machine-related losses from process inefficiencies
  • Manual, inconsistent data collection that delays decision-making
  • Difficulty tracking availability, performance, and quality metrics separately
  • Limited insight into root causes of production losses and the highest-impact improvement opportunities

Resulting Business Impact

  • Reduced throughput, equipment utilization, and overall manufacturing productivity
  • Increased downtime, maintenance costs, and extended recovery periods
  • Higher scrap, rework, and quality-related costs
  • Misallocated resources focused on low-impact problems
  • Reduced profitability due to hidden production losses and inefficient resource allocation

Effective OEE software must provide real-time monitoring, automated data collection, and clear prioritization of production losses to drive measurable improvements in availability, performance, and quality, enabling manufacturers to increase productivity and profitability.

The Solution: Automated OEE Monitoring and Analysis with GENESIS

GENESIS is an OEE software platform that automates the collection, calculation, and visualization of overall equipment effectiveness and its three core components: availability, performance, and quality. By connecting directly to PLCs, SCADA systems, historians, and enterprise data sources, GENESIS eliminates manual data collection and delivers real-time OEE visibility across every production line, shift, asset, and site.

With real-time visibility into OEE and production performance, manufacturers can identify production losses, reduce downtime, improve throughput, and focus resources on the highest-impact opportunities. Interactive dashboards, ad hoc trending, and scheduled reporting provide actionable insights that help teams uncover root causes, measure results, and drive continuous improvement across the enterprise.


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Real-time KPIs

Aggregate data from multiple sources and visualize performance metrics

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Asset Performance Analysis

Analyze downtime trends, production counts, cycle times, and time-in-state data to identify the root causes of OEE losses

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Compare Distributed Assets

Compare OEE scores and loss categories consistently across distributed assets, lines, and facilities

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Real-World Results and OEE Success Stories

Catania Oils

Food and Beverage Manufacturing

Catania Oils leveraged GENESIS to gain comprehensive visibility into production efficiency across multiple lines, products, and shifts. By monitoring OEE and loss deployment, the company identified targeted improvement opportunities and transitioned from calendar-based to predictive maintenance scheduling.

Result highlights:

  • Real-time OEE monitoring across all production lines
  • Clear distinction between machine losses and process inefficiencies
  • Data-driven maintenance scheduling reducing unplanned downtime
  • Daily automated reporting enabling faster decision-making

"We collect data regularly through GENESIS. And so, we get data from every line, from every product, and from every shift, and that data is accumulated in the database and a report comes out every day for us to be able to determine how each one of those lines is running."

Dan Bracket
Vice President of Operations, Catania Oils

PGT Industries

Manufacturing

PGT Industries uses GENESIS Productivity Analytics to measure and improve overall equipment effectiveness (OEE) across critical production assets. By analyzing availability, performance, and quality in real time, the platform identifies hidden inefficiencies, provides actionable insight, and enables teams to optimize production using existing capacity rather than expanding operations.

Result highlights:

  • Real-time visibility into OEE across production processes
  • Identification of hidden inefficiencies impacting availability, performance, and quality
  • Increased production capacity without capital expansion
  • Reduced labor and energy costs through optimized operations

"This system has been a great success and the production capacity found to exist in the current plants has exceeded any expectation."

Jon McArthur
Manufacturing Technology Engineer, PGT Industries

Business Benefits of Our OEE Solutions

Improve Production Efficiency

Continuous visibility into availability, performance losses, and quality deviations enables teams to identify inefficiencies early and drive measurable OEE improvement across lines and sites.

Prioritize Improvement Efforts

Cost- and impact-based prioritization helps teams focused on continuous improvement and operational excellence concentrate on the issues that matter most—reducing downtime, minimizing scrap, and maximizing throughput with limited resources.

Role-Based Insights

Role-based dashboards deliver the right performance metrics to operators, engineers, and managers—improving accountability, coordination, and data-driven decision-making at every level.

Rapid Time to Value

Preconfigured KPIs, templates, and interactive visualizations accelerate deployment and adoption—allowing manufacturing teams to move quickly from data collection to operational improvement.

GENESIS OEE Capabilities

Comprehensive KPI Measurement

Track OEE and other key manufacturing key performance indictors (KPIs) with automated calculations and reporting. Gain real-time visibility into availability (runtime vs. downtime), performance (actual speed vs. optimal speed), and quality (good units vs. total units) to maximize operational efficiency.

Detailed Analysis

Capture and analyze highly granular data to distinguish between machine-related losses and process inefficiencies to prioritize improvement efforts. Gain deeper insight into the entire production process and contributing factors for operational performance rather than focusing solely on individual equipment faults or quality defects.

Real-Time Visualization

Monitor throughput, utilization, yield, cycle time, and other critical KPIs in real time. Enable proactive intervention by alerting users when performance deviates from defined thresholds or operating parameters.

Universal Data Connectivity

Aggregate operational data from PLCs, SCADA systems, historians, MES platforms, and enterprise systems through SQL, SAP, Oracle, ODBC, OLE DB, OPC UA, MQTT, and other industry-standard protocols. Create a unified view of OEE and production performance across lines and sites, and across business intelligence tools, for comprehensive analysis.

Built for Operational Excellence

The GENESIS platform is often deployed as an operational performance solution due to its ability to integrate complex, heterogeneous Information Technology (IT) and Operational Technology (OT) environments while providing the flexibility required to define and calculate operational metrics.

OEE calculations often require production context that resides outside the control system. GENESIS incorporates contextual production data (e.g., batch IDs, recipe numbers, operator IDs, work orders, product codes, time standards, and shift schedules) from enterprise systems and databases. By combining real-time operational data with business context, GENESIS delivers OEE metrics and performance insights that reflect actual production conditions across lines, shifts, and sites.

OEE solutions marketecture diagram


GENESIS uses asset modeling and calculation engines to aggregate operational data and deliver KPI and metric outputs in dashboards, trends, and reports that can be tailored to the needs of different users.

Key platform capabilities:

  • Standards-based communications to devices, industrial control systems, and building automation
  • Flexible calculation frameworks and downtime analytics that reduce configuration effort
  • Enterprise system integration supporting information exchange for lean manufacturing initiatives
  • Role-based access and customizable views for operators, engineers, and executives
  • Automated report generation and distribution on configurable schedules
  • Mobile access enabling monitoring and decision-making from any device

By combining highly accurate real-time information with comprehensive historical analysis, GENESIS enables organizations to drive global operational efficiency and gain a competitive advantage.

Learn More About Our OEE Solutions

Digital Transformation Guide

Learn how to assess your digital transformation needs and leverage OEE as a foundation for continuous improvement initiatives.

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GENESIS Platform Brochure

Learn how the GENESIS platform unifies OEE monitoring, alarm management, visualization, analytics, and operational intelligence across industrial and building environments.

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Frequently Asked Questions

What is OEE in manufacturing?
Overall equipment effectiveness (OEE) is a manufacturing performance metric used to evaluate how effectively equipment, production lines, and facilities are operating. OEE helps manufacturers understand the impact of downtime, speed losses, and quality issues on overall productivity, making it easier to identify production losses and prioritize improvement efforts.

By providing a standardized measure of manufacturing performance, OEE enables organizations to benchmark assets, track continuous improvement initiatives, and increase production capacity without additional capital investment.

How do you calculate OEE?
OEE = Availability × Performance × Quality

Availability measures planned production time versus actual runtime. Performance measures actual production speed versus ideal production speed. Quality measures the percentage of good units produced versus total units produced. Together, these metrics provide a comprehensive view of manufacturing efficiency.

How can manufacturers improve OEE?
Manufacturers can improve OEE by reducing downtime, eliminating performance bottlenecks, improving product quality, and addressing the root causes of production losses. Real-time OEE monitoring helps teams identify inefficiencies, prioritize corrective actions, and measure the impact of continuous improvement initiatives over time.

Can GENESIS monitor OEE across multiple production lines and facilities?
Yes. GENESIS provides enterprise-wide visibility into OEE across machines, production lines, shifts, plants, and distributed manufacturing facilities. Role-based dashboards, trends, and reports enable consistent performance measurement across the organization..

How does GENESIS help improve OEE?
GENESIS helps manufacturers improve OEE by automatically collecting and contextualizing data from production equipment, control systems, and enterprise applications. Unlike solutions that rely solely on machine data, GENESIS combines operational and business information to provide a more complete view of manufacturing performance. This enables more accurate OEE measurement, consistent performance benchmarking across assets and facilities, and better-informed operational decisions.

Take the Next Step

Request a personalized demo to see how GENESIS by Mitsubishi Electric Iconics Digital Solutions can help you improve OEE and transform your industrial operations.

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