What is the biggest OEE challenge in high-speed manufacturing?
The biggest challenge is "Performance Leakage," caused by unrecorded micro-stops and speed variations. In high-speed lines, traditional OEE tools fail to capture stops under 60 seconds, which can accumulate into a 15% capacity loss.
A modern "System of Action" solves this by visually capturing every stoppage and automatically triggering the maintenance cure in the CMMS.
1. Fabrico: The System of Action for High-Speed Flow
Fabrico is built for manufacturers who have realized that dashboards alone don't increase output. It is the only platform that unifies real-time OEE monitoring with a technician-friendly CMMS and Computer Vision.
Micro-Stop Detection (Zoom-In Feature): While generic OEE tools rely on manual operator input to code downtime, Fabrico uses Computer Vision to capture video clips of the exact moment a line stops. This allows Mike (the CI Manager) to differentiate between a raw material defect and a mechanical misalignment in seconds, not days.
Condition-Directed (CD) Maintenance: Fabrico uses the Smith & Hinchcliffe Framework to move maintenance from the calendar to the machine's actual health. If OEE performance on a labeling unit drops below 92%, the system "pulls" a prioritized task to Tom (the Technician) before a full breakdown occurs.
Interactive Planning Board: This module ensures that production schedules are based on the true availability of the line. By syncing with the CMMS, it prevents planners from scheduling high-speed runs on assets that are currently being flagged for performance degradation.
2. Sepasoft (MES for Ignition)
Sepasoft is a robust module for the Ignition SCADA platform, widely used for deep enterprise-level OEE and MES.
3. OEE Systems International (Performix)
A specialist in "The Science of Manufacturing Performance" with a long history in high-speed pharmaceutical and food lines.
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The Gap: While its analytical depth is impressive, it is often siloed from the maintenance workshop. Without a native CMMS loop, it remains a "System of Diagnosis." The gap between the OEE report and the technical repair remains a manual, friction-filled process.
4. MachineMetrics (The IIoT Data Specialist)
MachineMetrics excels at high-fidelity data collection, providing deep insights into machine health and OEE for discrete high-speed manufacturing.
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The Gap: It is an elite production monitoring tool, but it lacks the full-cycle maintenance execution layer. To manage MRO inventory, spare parts, and complex RCM hierarchies, you still need to integrate an external CMMS, re-creating a data silo.
5. Evocon (The Cloud UX Specialist)
Evocon is praised for its simplicity and fast setup time, providing high visibility into downtime with a very low learning curve.
High-Speed OEE Comparison Matrix
| Feature |
Fabrico |
Sepasoft |
OEE Systems |
MachineMetrics |
Evocon |
| Unified OEE & CMMS |
✅ Native |
❌ No |
❌ No |
❌ No |
❌ No |
| Micro-stop Video RCA |
✅ Confirmed |
❌ No |
❌ No |
❌ No |
❌ No |
| Fault-to-Fix Speed |
✅ Instant |
❌ Lagging |
❌ Lagging |
⚠️ Moderate |
⚠️ Moderate |
| Technician Adoption |
✅ 96% |
❌ Low |
⚠️ Moderate |
❌ N/A |
✅ High |
| RCM & CD Logic |
✅ Advanced |
✅ Advanced |
✅ Advanced |
❌ Limited |
❌ Basic |
The ROI of "Performance Intelligence"
For Paula (the Strategic Leader), the goal is to increase ROA (Return on Assets).
In high-speed production, buying more machines is rarely the answer; recovering the "Hidden Factory" is.
By unifying OEE data and maintenance execution into a single "System of Action," Fabrico ensures that your most expensive technical resources are always focused on the "Bad Actor" assets that are bleeding your profit. It’s the difference between seeing your problems and actually fixing them.
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