What is the OEE Visibility Gap in manufacturing?
The OEE Visibility Gap is the technical discrepancy between the downtime events captured by traditional machine sensors (PLCs) and the actual, frequent micro-stops and slow cycles that occur on the shop floor, which often go unrecorded because they are too short for manual logging or too complex for basic signal logic.
For Mike (the Tactical Manager), this gap is a source of constant "Post-Mortem" frustration.
He sees a performance loss on a Friday report but has no data to prove if the cause was a material defect or an operator adjustment.
Fabrico eliminates this gap by utilizing the Visibility Trifecta to capture 100% of the operational truth in real-time.
Dimension 1: Machine Signals (The Digital Pulse)
Every OEE strategy begins with direct machine connectivity via PLC or IoT gateways.
This provides the millisecond-accurate timing required to measure Availability and Performance.
However, sensors are "Context-Blind"—they cannot tell the difference between a mechanical failure and an upstream bottleneck.
Fabrico pulls this "Pulse" data and uses it as the baseline trigger for the rest of your System of Action.
Dimension 2: Operator Context (The Human Intent)
The person standing at the machine often knows exactly why the line is running slow, yet their knowledge is rarely captured in a digital format.
Fabrico provides a Field-Ready mobile interface that allows operators to add context to a downtime event in seconds.
By combining machine data with human input, you move from "Data-Rich" to "Insight-Rich."
This ensures that Tom (the Technician) receives a Work Order that includes the operator's notes on material quality or environmental factors.
Dimension 3: Computer Vision (The Undeniable Truth)
In high-speed Food & Beverage or Plastics lines, events happen too fast for humans to remember accurately.
Fabrico’s Inefficiencies Zoom-In (Computer Vision) module acts as the "Eyes" of your continuous improvement team.
When a micro-stop occurs, the system flags a 10-second video clip of the exact moment of failure.
This visual evidence allows Mike to see if the jam was caused by a vibrating guide rail or a misaligned feeder, providing the proof needed for a permanent mechanical fix.
Comparison Matrix: OEE Visibility Strategies
| Capability |
Standard PLC Monitoring |
Manual Operator Logs |
Fabrico (System of Action) |
| Micro-stop Detection |
High (Timing Only) |
Zero |
Absolute (Timing + Visual) |
| Root Cause Depth |
Data-Only / Guessing |
Subjective |
Advanced Visual Zoom-In |
| Maintenance Link |
None / Siled |
Manual Request |
Native Integrated CMMS |
| Decision Latency |
Moderate |
Very High |
Zero (Automated Triggers) |
| Audit Readiness |
Low |
Low (Pencil Whipped) |
Instant (Digital Trail) |
| ROI Strategy |
Reporting |
Compliance |
Revenue Reclamation |
ROI: From Visual Proof to Maintenance Execution
For Paula (the Strategic Leader), the goal of 100% visibility is to reduce the Maintenance Cost per Unit.
By identifying "Bad Actor" assets through the 80/20 Rule and providing visual proof of failure, she can move her team to Condition-Directed Tasks.
Reclaiming just 10 minutes of "Invisible Loss" per shift can generate a 300% ROI on your software investment within the first six months.
This data-driven foundation is also the prerequisite for the Fabrico Agent (AI Roadmap), which will eventually automate these diagnostic cycles.
Stop guessing your OEE. Start seeing the truth with a System of Action.
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