Manufacturing · OEE improvement
Your real OEE is lower than the number in the spreadsheet
Speed losses and micro-stoppages under five minutes never make it into a downtime log. That gap — between reported OEE and actual OEE — is where most manufacturers lose 15–30% of capacity without ever seeing it on a report.
Banao wires OEE calculation directly to your PLC and sensor signals, calculates availability, performance, and quality losses in real time, and surfaces the constraint machine before the shift ends — not after the weekly review.
The first call is free · 45 minutes · no obligation
What we build
What a Banao OEE deployment includes
OEE is only useful when it is current, complete, and tied to a specific loss category. We build the pipeline that makes all three true.
Real-time OEE from your existing PLC signals
We tap machine state signals — run, idle, fault, speed — directly from PLCs and SCADA, calculate OEE in real time, and write it to a shift dashboard. No manual data entry, no end-of-day delay.
Micro-stoppage capture
Stoppages under five minutes never get logged but compound into hours of lost production per week. We capture them automatically from machine state transitions and show cumulative impact by machine and shift.
Speed loss detection
We compare actual cycle times against your rated speed and flag when a machine is running below nameplate capacity — usually a tooling, feed, or upstream supply issue that operators do not escalate.
Downtime classification without manual coding
Machine state and alarm codes are mapped automatically to a downtime taxonomy. Operators confirm or correct; those corrections train the classifier so manual coding effort falls over time.
Bottleneck and constraint identification
Which machine is limiting your line throughput right now? We calculate constraint shifts across your cell and surface the answer before the planning meeting — not in the post-mortem.
Shift and machine comparison dashboard
Plant heads see OEE by machine, by shift, and by crew — so a performance gap between day and night shifts is visible in the data, not just in a supervisor's impression.
Dogfooding
We run our own operations on the same AI we sell
Banao operates a ~300-person engineering company on its own AI products before any client sees them. InterviewGod screens our own engineering hires. Vikaas runs our own demand generation. We do not advise on production AI from the outside — we depend on it internally.
An OEE system that has to survive real operational scrutiny inside Banao is already tested before it reaches your floor. That is a different standard from a demo built for a sales meeting.
Screens Banao's own engineering hires every week.
Runs Banao's own demand-gen pipeline end to end.
The honest version
When OEE analytics is the wrong investment
OEE tracking reveals losses. It does not fix them. Before we quote, we check whether the economics make sense:
- High OEE lines: if your OEE is already above 85%, the remaining gains are marginal and may not repay instrumentation and build cost. We will tell you this in the Discovery Sprint.
- Chronic process defects: if the root cause of your losses is a machine that needs capital overhaul or a process that is fundamentally misdesigned, better OEE data will confirm the problem — but the fix is not software.
- No PLC or machine signal access: if machines produce no digital signal at all, week one is instrumentation. We can scope that work, but the OEE project starts after connectivity exists, not before.
How we start
How we start — see your real OEE before committing to a build
We audit one cell, calculate its actual OEE from raw signals, and show you the gap between reported and real before you spend on a full deployment.
- 01
AI Discovery Sprint
2 weeks · fixed price
We connect to one cell, compute its real OEE over the Sprint window, identify the top three loss buckets, and hand back a go/no-go with the business case — yours to keep either way. If you proceed, the Sprint cost is credited against the build.
- 02
Build
PLC and SCADA integration across selected lines, automated downtime classification, and a plant dashboard. Old-kit integration is part of the deliverable — we do not require a hardware refresh to start.
- 03
Production & continuous improvement
Live OEE dashboard, operator correction loop for downtime coding, and a quarterly loss-review cadence with your plant team so the data drives action rather than accumulating.
FAQ
Frequently asked questions
How is this different from what our MES already shows us?
Most MES OEE figures rely on operator-entered downtime codes — which means short stoppages are missed, coding is inconsistent, and the number is only as good as last night's entry. Banao calculates OEE directly from machine state signals, so it is current, complete, and independent of manual input.
Do we need new sensors or hardware to start?
Usually not. We connect to existing PLC outputs, machine alarm registers, and SCADA historians first. New instrumentation is only specified where there is no digital signal at all — typically older manual machines with no PLC.
We already have a dashboard. Why build another one?
Most plant dashboards show availability — planned versus unplanned downtime. The Performance loss component (speed below rated, micro-stoppages) is rarely captured. If your current dashboard does not show speed loss and micro-stoppages by machine, the OEE number it reports is higher than reality.
How long before we see a real OEE number?
In the Discovery Sprint — typically within the first week of connection — you see the actual OEE for the cell we are monitoring. The gap between that number and what is currently being reported is usually what drives the decision to continue.
Can you connect to our ERP and production targets?
Yes. We pull planned production quantities and shift schedules from your ERP or planning system to calculate availability accurately. Order targets and actual output feed the performance calculation, and the dashboard shows OEE against plan.
Get started
Find out what your real OEE is
In 45 minutes we will identify which loss type — availability, performance, or quality — is costing you the most capacity, and what it would take to measure it accurately.
Book a Discovery Sprint