Reclaiming the 10%: How to Crush Micro-Stops with Computer Vision and Integrated OEE

The "OEE Performance Trap" in High-Speed Lines

Why do traditional OEE systems fail to reduce micro-stops?
Traditional OEE systems rely on PLC signals that only register "Running" or "Stopped." They lack the contextual intelligence to explain if a stop was caused by a material defect, an operator adjustment, or a mechanical misalignment, leading to a perpetual cycle of "firefighting" without resolution.

In a packaging or bottling plant, a micro-stop occurs so frequently that operators often view it as part of the machine's "personality." This is a dangerous trap. For Mike, the Maintenance Manager, these stops are symptoms of underlying "Bad Actor" components.

Without Integrated OEE and CMMS, these symptoms never escalate into a permanent fix. They remain "Performance Losses" that frustrate the team and bleed the bottom line.

Beyond the Sensor: The Power of Inefficiencies Zoom-In

Fabrico bridges the "Context Gap" by utilizing Computer Vision (CV). While a sensor can count a bottle on a conveyor, it cannot tell you why the bottle tipped over.

1. Visual Evidence over Text Logs: When a machine stops, Fabrico automatically flags the timestamp and clips the video footage from the overhead camera. This allows Mike to "Zoom-In" and see exactly what happened—no interviews required.

2. AI-Suggested Tagging: By learning from historical data, the system suggests likely causes (e.g., "Infeed Jam" or "No Material"). This eliminates "Pencil Whipping" where operators simply select "Unknown" to save time.

3. The "Value Fulcrum" for Maintenance: Once the micro-stop is identified as a recurring mechanical issue, Fabrico’s System of Action automatically creates a prioritized Work Order. We prioritize the fix based on its impact on Effective Runtime, not just the order in which it broke.

Comparison Matrix: Traditional OEE vs. Fabrico Visual Intelligence

The Financial Case: Reclaiming Your Effective Runtime

For Paula (the Strategic Leader), micro-stops are a direct drain on Maintenance Cost per Unit. If your machines are stopping 40 times a shift for two minutes each, you are losing over an hour of production daily—roughly 12.5% of your capacity.

By implementing a Field-Ready CMMS that is natively tied to these micro-stops, you reclaim this capacity without buying a single new machine.

• Reduce Scrap Rate: Many micro-stops result in "Start-Stop" quality defects. Stabilizing the flow reduces the volume of bad parts.

• Optimize SMED (Single-Minute Exchange of Die): Use Computer Vision to analyze changeovers and identify "Waste Motion" to get the line back to full speed faster.

• Standardize Tribal Knowledge: When the Assistant (Roadmap) sees a recurring fault, it provides the technician with the exact SOP to fix it, ensuring the "Night Shift" fix is as good as the "Day Shift" fix.

Stop guessing why your machines are stopping. See the truth, fix the cause, and reclaim your OEE.