How long does a unified OEE and CMMS implementation take?
A unified OEE and CMMS implementation typically takes 90 to 120 days to achieve full operational value. The roadmap consists of four phases:
1. Strategic Scoping (Days 1-15) to identify bottlenecks;
2. Pilot Site Setup (Days 16-45) using PLC and Computer Vision;
3. Technician Adoption (Days 46-75) to launch the CMMS loop; and
4. Continuous Improvement Scaling (Days 76-90) where OEE data triggers automated technical cures.
Phase 1: Identifying the "Value Fulcrum"
Paula, the Strategic Leader, needs a high ROI with minimal risk. Following the Robert C. Hansen Framework, we begin by identifying the "Value Fulcrum"—the specific production line where small efficiency gains will have the largest impact on total throughput.
Using the 80/20 Rule of RCM, Mike (the Plant Manager) should select the "Bad Actor" assets: the 20% of machines currently responsible for 80% of unplanned downtime. This ensures that the pilot project generates measurable revenue gains within the first 30 days.
Phase 2: Building the "System of Action"
Most OEE projects fail because they provide "Data without Action." In this phase, we establish Unified Data Intelligence. We connect PLCs to capture Availability, but we also deploy Computer Vision (Inefficiencies Zoom-In) to capture the "Invisible Losses."
By using overhead cameras, we catch the 30-second jams and operator hesitations that standard sensors miss. This visual evidence creates a "Digital Truth" that replaces tribal knowledge. When a line stops, the system doesn't just record a loss; it provides the video proof needed for a 100% accurate Root Cause Analysis (RCA).
Phase 3: Moving from "Push" to "Pull" Maintenance
This is where Tom (the Technician) enters the roadmap. To ensure high adoption, the system must be "Field-Ready." We replace paper binders with a mobile-first CMMS that Tom actually wants to use.
Following the Smith & Hinchcliffe RCM logic, we move away from calendar-based "Push" maintenance. Instead, the OEE module "Pulls" maintenance by triggering Condition-Directed (CD) Tasks. If performance efficiency drops below a set threshold, a prioritized work order is pushed to Tom's mobile device instantly, closing the "Fault-to-Fix" loop.
Phase 4: Scaling the "Toyota Template"
In the final 30 days, we apply the "Plant First" commitment of the Toyota Template. We move from one bottleneck line to the entire plant. We standardize the "Maintenance Patois"—ensuring every technician across every shift uses the same failure codes and digital SOPs.
The Interactive Planning Board is now synced with real-time machine availability. Production schedules are no longer based on assumptions; they are reactive to the technical reality of the floor, ensuring Paula can promise delivery dates with 100% confidence.
The Implementation Matrix: Pilot vs. Scaled Action
| Milestone |
Phase 1: Scoping |
Phase 2: Pilot Line |
Phase 3: CMMS Loop |
Phase 4: World Class |
| Data Focus |
Financial ROA |
Micro-stop Detection |
Fault-to-Fix Speed |
TEEP Recovery |
| Technology |
Data Analysis |
PLC + Computer Vision |
Mobile CMMS App |
Interactive Planning |
| Logic |
80/20 Bad Actors |
Visual Validation |
CD Task Triggers |
Global Standards |
| User Role |
Paula (COO) |
Mike (CI Manager) |
Tom (Technician) |
The Entire Enterprise |
| Goal |
Scoping the Loss |
Recovering Capacity |
Reducing MTTR |
Sustaining OEE |
Strategic Verdict: The Roadmap to Profit
An OEE and CMMS implementation is not an IT project; it is a revenue recovery strategy. By unifying the diagnosis and the cure, you eliminate the "Silo Tax" that keeps most plants in a state of reactive chaos.
Fabrico is designed for the "Field-Ready" manufacturer. By identifying your Bad Actors and automating the technical response, we ensure your 90-day roadmap leads to a permanent increase in capacity and a world-class bottom line.
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