AI and IOT Solutions Blog: Stay Updated with AIoTmission

AIoT – Operational Technology

June 27, 2025June 27, 2025 by editor Comment Closed

Revisiting OT ( The operational Technology ) While talking to people is always enjoyable, making machines that can communicate with each other is even more fascinating!The shop floor used to be synonymous with earning extra through "OT" 😉 —overtime. But these days, "OT" has taken on a whole new dimension: Operational Technology. Our focus has shifted from extra hours to extra intelligence—connecting machines, sensors, and systems in smarter ways.When building efficient and reliable IIoT edge devices under resource constraints, the choice of operating system plays a vital role. And extracting data from Japanese PLCs brings its own set of challenges, thanks to their tightly guarded, proprietary communication methods.Revisiting OT—this time as the foundation for AI—marks the beginning of an exciting new chapter in our industrial transformation journey. The foundation of any AI initiative in manufacturing begins with effective shop floor data collection. One common challenge is integrating data from existing equipment, particularly when it involves legacy systems or machines automated with proprietary...

The power of OEE Distiller in handling 6 losses

May 25, 2025May 25, 2025 by editor Comment Closed

“You Don’t Need More Machines—You Need to Measure Losses Better”When customer orders keep piling in and production can’t keep up, the first instinct is often:“We need another machine and it cost 100K " But do you really need that?Let’s look at this scenario:You have 10 machines, each producing 100 units/day. You’re running at 60% OEE.New demand = 1,100 units/day (but you're only producing 1,000)So you’re 100 units short—and considering spending $100,000 on a new line👉 But what if the capacity you need is already there—hidden inside inefficiencies? By understanding and addressing the 6 Big Losses of OEE—(like minor stops, reduced speed, and quality issues)—you improve your OEE from 60% to 70%.That 10% increase now means each machine produces 110 units/day.End Result:10 machines × 110 units = 1,100 units/dayNo new machine needed$100K investment savedAnd long-term gains through sustained efficiencyThe Takeaway ( by distilling your efficiency with the tracking of 6 key losses) :Tracking the 6 Key OEE Losses isn’t just about monitoring...

The power of OEE 6 key losses

May 4, 2025May 25, 2025 by editor Comment Closed

You Don’t Need More Machines—You Need to Measure Losses Better Why Tracking the 6 Key OEE Losses Is More Critical Than You ThinkWhen customer orders keep piling in and production can’t keep up, the first instinct is often:“We need another machine.”But do you really?Let’s look at this scenario:You have 10 machines, each producing 100 units/dayYou’re running at 60% OEENew demand = 1,100 units/day (but you're only producing 1,000)So you’re 100 units short—and considering spending $100,000 on a new line👉 But what if the capacity you need is already there—hidden inside inefficiencies?By understanding and addressing the 6 Big Losses of OEE—(like minor stops, reduced speed, and quality issues)—you improve your OEE from 60% to 70%.That 10% increase now means each machine produces 110 units/day. Result: 10 machines × 110 units = 1,100 units/day No new machine needed $100K investment saved And long-term gains through sustained efficiency The Takeaway:Tracking the 6 Key OEE Losses isn’t just about monitoring performance—it’s about unlocking trapped capacity, avoiding unnecessary investments, and turning existing...

OEE Six Big losses #6 The Start up Defects

April 27, 2025May 5, 2025 by editor Comment Closed

6 key losses -The start up Defects Understanding Start-Up Rejects in OEE: A Hidden Quality DrainWithin the framework of Overall Equipment Effectiveness (OEE), Quality stands as one of the three core pillars, alongside Availability and Performance. While many manufacturers focus on production-time defects, a less-discussed yet equally critical source of quality loss is the Start-up Reject—a type of defect that occurs immediately after a machine or line begins operation. What Are Start-Up Rejects?Start-up rejects are defective units produced during the initial phase of machine operation—either at the beginning of a shift, after a changeover, or following maintenance or equipment downtime. These are not incidental flaws; they are often symptomatic of deeper inefficiencies in the warm-up or ramp-up phase of production.These defects usually happen because machines, tools, or processes haven't reached optimal operational conditions. Factors like temperature stabilization, incorrect calibration, residual materials, or operator oversight during start-up can all contribute to this issue. Why Start-Up Rejects MatterAlthough they might seem insignificant in isolation, start-up rejects...

OEE 6 Big losses #5 The production Defects

April 19, 2025May 1, 2025 by editor Comment Closed

OEE 6 Big Losses - The production Defects The Power of OEE The beauty of OEE (Overall Equipment Effectiveness) lies in its comprehensive nature—it encapsulates all the essential components that define a meaningful key performance indicator (KPI) in manufacturing operations.Among the three core components of OEE—Availability, Performance, and Quality—Quality plays a critical role. Without producing a high number of good-quality units, speed and efficiency become irrelevant. No matter how fast or uninterrupted your production is, if the output is flawed, it diminishes the overall value. The beauty of OEE (Overall Equipment Effectiveness) lies in its comprehensive nature—it encapsulates all the essential components that define a meaningful key performance indicator (KPI) in manufacturing operations.Among the three core components of OEE—Availability, Performance, and Quality—Quality plays a critical role. Without producing a high number of good-quality units, speed and efficiency become irrelevant. No matter how fast or uninterrupted your production is, if the output is flawed, it diminishes the overall value.One of the "Six Big...

OEE 6 big losses #4 The small Stop

April 12, 2025May 14, 2025 by editor Comment Closed

OEE 6 Big losses -The Small Stop While it is SMALL, it can also be very BIG! 🤪 There we go again ... 6 Big OEE losses #4-The Small Stop Best way to understand small stop is like traveling on a journey towards a destination, along the way, you are estimating to reach the destination say in 1 hour, along the roadyou bump into a traffic jam, road blockages, accidents etc. These are the small stops. In the production process, minor disruptions often occur due to waiting for materials to run, delay in restarting machines after the disruption, equipment misalignment, or jam-ups. These are the common small stops that we have been focusing on.Some advance processes have built-in functions that detect the cause of these stops. These systems may rely on Stack light indicator or internal controller like PLCs to detect error codes related to the disruption. Why are these small stops important? As you know when the production is running 24 hours daily,...

Six Big Losses #3 -The Slow Cycle

April 7, 2025May 1, 2025 by editor Comment Closed

Six Big Losses in OEE #3 The Slow Cycle SLOW --> BIG !😉 Why? When it is concerning the heartbeat of the production, so it is BIG!🧨The 6 Big losses #3 -The Slow Cycle.In any manufacturing environment, cycle time is more than just a metric—it's the heartbeat of the production system. Each completed cycle represents a unit of output, and when those beats slow down, so does productivity.That’s why monitoring cycle time is so critical. It tells you, in real time, whether your production line is healthy and performing at its best—or if there are hidden inefficiencies slowing things down.When you walk through a modern production floor, you’ll often see digital boards displaying Target Output vs. Actual Output. This real-time feedback loop creates operator awareness, helping them stay aligned with expected production goals. It also acts as a subtle productivity cue, letting teams know if the "heartbeat" of the process is slowing.This slowdown—known as a slow cycle—can be caused by...

Six key losses in OEE -The Planned Stop

April 2, 2025April 2, 2025 by editor Comment Closed

The Planned Stop - Six OEE Big Losses We can understand unplanned downtime, but why planned stop? 🤔In manufacturing, planned stops represent a major category of production losses and it is part of the OEE six big losses. These are intentional halts in machine operation—such as for model changes, tool changes, or scheduled maintenance—that can heavily impact OEE (Overall Equipment Effectiveness) if not managed properly.A key tool in managing and visualizing these stops is the Andon system—a real-time visual indicator (typically using stack lights with 3 or 4 colors) that communicates machine or process status directly from the production floor. A red or blue light, for instance, may signal a planned stop, alerting operators and maintenance teams in real time.While planned downtime is necessary, poor planning or execution can erode process availability and drag down your OEE score. That’s why tracking and optimizing these stops is vital.Common Causes of Planned Stops:* Model or Tool Changes – Switching between product variants requires precise...

The 6 Big Losses in OEE – Deep Dive into Unplanned Downtime

March 23, 2025March 23, 2025 by editor Comment Closed

The 6 Big Losses in OEE – Deep Dive into Unplanned DowntimeIn the world of manufacturing, where efficiency defines competitiveness, OEE (Overall Equipment Effectiveness) serves as a critical performance benchmark. Among the six major losses that OEE identifies, Unplanned Downtime stands out as a particularly disruptive and costly factor — especially in modern, automated environments.Let’s take a closer look at what unplanned downtime really means, its cascading effects on operations, and how manufacturers can tackle it more effectively using predictive AI-powered maintenance.What Is Unplanned Downtime?Unplanned downtime refers to any unexpected stoppage of production caused by equipment failure or unforeseen malfunctions. Unlike scheduled maintenance or planned shutdowns, these interruptions catch production teams off guard — causing a sudden halt in operations and often requiring emergency repairs or adjustments.With today's increasing reliance on automation, the risks associated with unplanned downtime have multiplied. For manufacturers operating under lean principles or Just-in-Time (JIT) strategies, even a short delay can have a "cabin effect" — where a minor...

Understanding the Six Big Losses in Manufacturing: A Roadmap to Greater Efficiency

January 18, 2025March 23, 2025 by editor Comment Closed

Understanding the Six Big Losses in Manufacturing: A Roadmap to Greater EfficiencyWhen you step onto a production floor, you’re immediately immersed in an atmosphere of intensity and focus. It’s a space where every individual, machine, and process is aligned with a singular purpose: maximizing output. Love it or not, this relentless pursuit of efficiency forms the core of manufacturing operations.In this high-pressure environment, companies rely on metrics to track and enhance productivity. Among these, one metric stands out as the gold standard: Overall Equipment Effectiveness (OEE). OEE is a universal benchmark in manufacturing, measuring how well a production process performs using the formula:OEE = Availability × Performance × Quality.This formula distills productivity into three essential components, providing a comprehensive view of where improvements can be made. The concept of OEE was introduced by Seiichi Nakajima, a visionary in manufacturing and the creator of the Total Productive Maintenance (TPM) system in the 1960s. His work laid the foundation for Japan’s global...