Manufacturing OEE
data acquisition
Production counts, run and stop status and fault codes collected from machine controllers over Modbus, time-stamped and delivered as the raw material for a reliable OEE figure.
THE PROBLEM
OEE built on handwritten logs measures the logbook
OEE is availability times performance times quality. Each of those terms needs data: when the machine ran and stopped, how many parts it made against its ideal rate, and how many were good. On many lines that data comes from an operator's end-of-shift notes, filled in from memory.
The machine PLC already knows the truth. It counts cycles, holds a run bit and a fault word, and often counts rejects. Reading those registers continuously gives an honest record of every stop, however short.
The harder part is meaning. A part counter might count strokes, good parts or every cavity. A stop might be a breakdown, a changeover or a planned break. Getting OEE right means agreeing those definitions first.
HOW WE SET IT UP
Clean signals first, OEE second
Agree the production semantics
With your production and controls engineers we define what each counter means, what counts as a stop, the ideal cycle time and how rejects are recorded. That definition is the foundation for every figure that follows.
Read counters and states
The gateway reads part counters, run and stop bits and fault codes from each machine PLC over Modbus RTU or TCP, at an interval short enough to catch short stops.
Validate against the line
For an agreed period the acquired counts and stops are compared with what actually happened on the line, so the OEE calculation is trusted before it reaches a management report.
Feed your OEE tool
The time-stamped data goes to RIOD Live or to your MES, BI or OEE software through an API, where the calculation and dashboards live.
AT A GLANCE
OEE data acquisition in brief
- What is read
- Part and reject counts, run and stop status, fault codes, mode, from machine PLCs and controllers
- Hardware
- RS485 Modbus IoT gateway, Modbus RTU over RS485 and Modbus TCP over Ethernet, master or slave
- Connectivity
- Ethernet, Wi-Fi or 4G, chosen per site. MQTT over TLS 1.2
- Power
- 12 V adapter from the panel supply, in a plastic, metal or custom enclosure
- Where data goes
- RIOD Live, your server, or your MES, BI or OEE software through an API. AI access through MCP
- Calculation
- OEE is calculated from validated production definitions agreed with your team
- Machine scope
- Machines whose controllers expose counters and states over Modbus, confirmed per machine
FAQ
Questions buyers ask us
What data do you need from a machine to calculate OEE?
Run and stop status with time stamps for availability, a part counter and ideal cycle time for performance, and a good or reject count for quality. Most PLCs hold these values, and they can be read over Modbus.
Can OEE data be collected automatically from older machines?
Yes, if the machine controller exposes counters and status over Modbus RTU or TCP. We confirm each machine during the survey and agree the register list with the machine programmer.
Why do production definitions matter for OEE?
A counter may count strokes, cavities or good parts, and a stop may be a breakdown or a planned changeover. Unless those meanings are agreed and validated against the line, the OEE figure will be precise but wrong.
Can the machine data go into our MES or BI tool?
Yes. Data is available through an API from RIOD Live or your own server, so your MES, BI or OEE software can calculate and display it.
Want OEE you can trust?
Tell us the machines, their controllers and how OEE is measured today. We will propose the data points and the validation plan.