Measure What Matters. Improve What Counts.
Every manufacturer wants to run faster, reduce waste, and eliminate unplanned downtime. But you can't improve what you can't measure. ICS builds complete OEE and MES solutions on the Ignition platform with Sepasoft modules that give you real-time visibility into your Availability, Performance, and Quality — so you know exactly where you're losing production and how to fix it.
Overall Equipment Effectiveness (OEE) is the gold standard for measuring manufacturing productivity. It combines three critical factors into a single percentage:
Are we running when we should be? Measures the percentage of scheduled time that equipment is actually operating. Lost to breakdowns, changeovers, material shortages, or planned maintenance.
Are we running as fast as we should? Compares actual production speed to the ideal speed. Lost when running slower than designed — worn tooling, operator inexperience, jams, or minor stops.
Are we making good parts? The ratio of good parts to total parts produced. Lost to scrap, rework, defects, or startup rejects. Includes anything that doesn't meet spec on the first pass.
Most manufacturing plants average around 60% OEE. World-class is 85%+. Even small improvements translate directly to increased capacity without adding equipment or labor.
Every minute of lost production falls into one of six categories. Our OEE system tracks all of them automatically.
| Category | Loss Type | What It Means |
|---|---|---|
| Availability | 1. Equipment Failure | Unplanned stops — breakdowns, faults, tooling failures. Tracked by MTBF and MTTR. |
| Availability | 2. Setup & Changeover | Time lost switching between products or adjusting equipment. |
| Performance | 3. Minor Stops & Idling | Brief interruptions under 5 minutes — sensor triggers, jams, blocked discharge. |
| Performance | 4. Speed Loss | Running slower than ideal cycle time. Caused by worn equipment or material variability. |
| Quality | 5. Defects & Rework | Parts that don't meet quality standards during steady-state production. |
| Quality | 6. Startup Rejects | Scrap produced during warm-up, ramp-up after changeover, or process stabilization. |
ICS builds OEE and MES solutions on the most powerful and flexible industrial software platform available.
The industrial application platform with unlimited licensing. Connect as many clients, screens, tags, and connections as you need — no additional cost. Web-based, cross-platform, and built for enterprise scale.
Purpose-built MES modules for OEE tracking, SPC, Track & Trace, scheduling, and batch management. The leading MES solution for the Ignition platform, used by manufacturers worldwide.
| Feature | Why It Matters |
|---|---|
| Unlimited clients and screens | Every operator, supervisor, and manager gets real-time access — no extra licenses |
| Web-based HMI/SCADA | Access dashboards from any device with a browser — plant floor, office, or mobile |
| Cross-platform compatibility | Runs on Windows, Linux, macOS — deploy on existing hardware |
| Built-in historian | Store years of production data for trending, analysis, and compliance |
| SQL database connectivity | Connect to any database for enterprise reporting and business intelligence |
| Multi-site architecture | Scale from a single machine to enterprise-wide deployment across facilities |
| Module | What It Does |
|---|---|
| OEE Downtime | Automatically tracks Availability, Performance, and Quality. Categorizes downtime events and provides Pareto analysis of losses. |
| SPC | Statistical Process Control with control charts, capability analysis (Cp/Cpk), and automated out-of-spec alerts. |
| Track & Trace | Full genealogy tracking from raw materials through finished goods. Essential for recalls and compliance. |
| Recipe/Batch | ISA-88 compliant batch management. Configure recipes, manage equipment phases, and ensure consistent production. |
| Scheduling | Production scheduling with drag-and-drop interface. Optimize changeovers and sync with ERP systems. |
| Settings & Changeover | Manage equipment settings per product. Auto-push setpoints to PLCs during changeovers. |
MES bridges the gap between your plant floor and your business systems. While ERP tells you what to make and when, MES tells you how it's actually going — in real time.
Real-time production dashboards, work order tracking, live vs. planned comparison, and material consumption tracking.
SPC charts and control limits, automated quality checks, full product genealogy/traceability, and non-conformance management.
Automated downtime categorization, changeover optimization, labor tracking, and ERP integration (SAP, Oracle, etc.).
ICS has developed MannyAI, our proprietary AI-powered manufacturing intelligence platform that works alongside your Ignition + Sepasoft OEE system:
See it live: manny.indconsys.com
Where does your facility stand?
Moving from 60% to 85% OEE effectively adds 40% more capacity to your existing equipment — without buying a single new machine.
Whether you're starting from scratch with OEE tracking or looking to upgrade from manual data collection, ICS can design and deploy a complete solution tailored to your operation.
Schedule a Consultation See Our OEE DashboardOr call us directly: (417) 624-2331
