Key Takeaways
Manual OEE data collection is cheap to start but can cost a fortune in inaccurate decisions, wasted labor, and delayed responses.
Automated methods like PLC integration and Computer Vision provide real-time, trustworthy data for both modern and legacy equipment.
The most powerful solution is a hybrid system: one that combines automated data capture with simple operator input for context, and then integrates it all into a CMMS to trigger immediate action.
Mike, a Maintenance Manager, is trying to build a business case for a major machine overhaul. He pulls up a spreadsheet of downtime data, but he has a sinking feeling. He knows it’s flawed.
The numbers were logged hours after the fact by busy operators, scribbled on a sheet and entered later. Was Machine B really down for 90 minutes due to a mechanical fault, or was it a 60-minute jam and a 30-minute material shortage?
He can't confidently ask for a $50,000 investment based on a guess. This is the core problem with OEE: bad data leads to bad business decisions, from misallocating maintenance resources to replacing the wrong asset.
The method you use to collect OEE data directly determines the quality of your decisions. Let's break down the common approaches.
How it works: An operator, Tom, keeps a log sheet at his station. He manually notes production counts, downtime events, and reject reasons throughout his shift.
The Painful Reality: This method is slow, prone to errors, and always out of date. It’s an extra burden on the frontline team and delivers lagging, unreliable data that forces managers like Mike to make decisions based on old news.
How it works: A shared computer terminal is placed on the shop floor. Operators enter their production data directly into a spreadsheet at the end of their shift or during a lull.
The Marginal Improvement: While the data is now digital, it's still not real-time. This method is plagued by input errors, version control chaos, and a complete lack of integration into any maintenance workflow. It's a digital version of a broken process.
How it works: A direct digital connection is made to a machine's controller (PLC) or to attached sensors. This allows the system to automatically log cycles, machine status (running/stopped), and fault codes.
The Benefits: This is the gold standard for accuracy and timeliness. It provides a stream of real-time, objective data with no extra work required from the operator.
The Limitation: This is great for your new, high-tech equipment. But what about that 20-year-old mechanical press or the offline assembly station that doesn't have a modern PLC?
How it works: Think of a smart camera pointed at your machine. It can read an analog pressure gauge, watch a status light turn from green to red, or count finished goods moving down a conveyor belt.
The Game-Changing Benefit: Computer Vision allows you to get all the benefits of automation on your older, "un-connectable" legacy equipment. It’s like retrofitting your entire factory for the digital age, without the complex and costly rewiring.
The Fabrico Advantage: At Fabrico, we have integrated Computer Vision as a core data collection method. This ensures that every single asset in your plant, new or old, can become a source of real-time, actionable data.
This is the most important question you can ask: When your new Computer Vision system detects that a machine has stopped, what happens next?
Does it just update a chart in a dashboard? Or does it actually start the solution?
An alert has little value without action. This is where our core philosophy comes in. The true power of great data is unlocked when a downtime event—whether captured by a PLC or a camera—instantly and automatically triggers a work order in an integrated CMMS.
We don't believe in forcing you into a single, rigid method. Fabrico’s platform is a flexible, hybrid solution designed for the reality of the modern factory.
We combine the best of all worlds:
Automated Data (PLC & Vision) provides the ultimate accuracy and real-time speed.
Simple Operator Input (via mobile tablets) allows your team to add critical human context, like selecting a specific downtime reason from a pre-set dropdown menu.
This integrated model provides what no single method can on its own: perfect, real-time numbers enriched with the on-the-ground intelligence of your team.
Do I need to buy special cameras for Computer Vision?
No. Fabrico's computer vision technology is designed to work with a wide range of standard industrial or even off-the-shelf cameras, making it a cost-effective solution for retrofitting equipment.
How do you ensure operators provide accurate downtime reasons?
We make it incredibly simple. When a machine stops, a tablet at the station can present the operator with a simple, pre-defined list of reasons. Instead of writing a novel, they make one or two taps. This improves consistency, accuracy, and buy-in from the team.
How much of our equipment needs to be automated to see a benefit?
You can see a significant benefit by starting with just your single most critical or bottleneck machine. The key is to start with your biggest pain point and expand from there. A hybrid system allows you to automate where it makes sense and use simple manual inputs elsewhere.
Your OEE score is only as good as the data it's built on. Stop relying on flawed, manual methods that force you to make critical business decisions based on guesswork.
Ready to see how a modern, hybrid data collection system with Computer Vision and an integrated CMMS can transform your operations
Book a personalized demo of Fabrico today.
Schedule a 1-to-1 meeting with our experts or directly enroll in our Free Plan.
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