Operator Systems | OEE – Machine performance monitoring & Status
Operator OEE (Overall Equipment Effectiveness) software improves the performance of your resources to maximize your production output. | Machine Monitoring & Status | OPC & OPC UA | PLC
Operator Systems, OEE, OPC, PLC, Machine Status, Overall Equipment Effectiveness, Production control, Machine integration, Machine monitoring, Production optimization, LEAN, Key performance indicator, Production KPI, Manufacturing KPI, KPI, Continuous improvement, Mobile OEE
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OEE – Machine status and performance monitoring

Increase OEE and produce more using the same resources

The Operator OEE (Overall Equipment Effectiveness) gathers data from machine PLC through OPC and helps to improve the performance of your resources to maximize your production output.

Key benefits from real-time Machine Monitoring

  • Machine status monitoring and KPI (OEE) calculation in the real time.
  • Reduced time-to-action with real-time performance feedback.
  • Graphical view of the performance of your plant, department or specific machine or machine group (Machine Monitoring).
  • Automatic collection and aggregation of data directly from PLC or OPC server, delivered in real-time.
  • Relevant and accurate data at a low cost, with easy and simple connection to machines.
  • Monitoring of improvement activities and their results.
  • Ability to scale your IT landscape as your business evolves and your requirements grow.


Operator OEE helps you benchmark your plant and production processes and identify areas for improvement – all while leveraging your existing assets, resources and infrastructure.

PLC and machine status

OEE – OPC – OPC UA – PLC – Machine Monitoring – Machine Status

Proven, fast return on investment in the Operator Machine Status module

At a glance, you can have the “on-line” status of the machines or the line/machine positions that are handled at the terminal. The Operator OEE screen shows the machine status and performance on the shift/day level.


This functionality allows you to monitor real-time machine status (which machines are stopped, or operating at reduced or normal speed). It is a robust tool for identifying the exact amount of production losses and their reasons, as well as for calculating and showing the status of the most important KPIs (like OEE), in real-time.


It also allows you to view production operations and schedule execution progress. So on one screen you have detailed information about the production process execution. OEE can also be used to measure and document the improvements achieved by Lean initiatives.

Calculate ROI

Operator OEE software is easy to install, use and maintain, and delivery of immediate OEE gains of 5%–10% are commonly achieved. Operator Systems has proven successful implementations with a ROI in about 6–12 months.

Contact us and we will help you calculate the potential Return Of the Investment in the Operator OEE system or use the ROI calculator, which can be found in the upper right corner of our website.

Go mobile with Mobile OEE APP!

At Operator Systems, we know that mobile plant monitoring capabilities are becoming increasingly important to our clients. That’s why we created Operator OEE Mobile – a dedicated suite of applications for mobile devices that e.g. displays your current machine statuses from the Operator MES, in an easy-to-read format, or it make registration of Stop and Scrap codes mobile. In the Mobile Operator OEE APP, the status of each machine is listed, and the statuses are labeled and color-coded. The application also includes a column displaying the duration of each status.


The target form OEE is to keep the highest possible availability and performance. Therefor we have develop a Maintenance Alert & Tracking APP suite. This APP suite make it possible to alert the Maintenance department as soon as a machine has a critical stop or damage. The functionality is simple, the shop floor operator push a button and at the same time the Maintenance employees receive the alert on their Mobile Operator APP with exact information received from the OEE. They can then start a Maintenance workflow and the Operator solution make sure that all activities and events are traced and tracked.


Mobile OEE APPs are available for Apple and Android devices


Machine monitoring is a multi-level activity with multidimensional benefits. The aim of these activities is to implement changes that increase the efficiency of manufacturing companies, including improving the quality of manufacturing products, optimizing equipment operation and reducing energy consumption. To make it possible, it is necessary to precisely determine the technical condition of machines: continuously observe machine status, their efficiency and to check the quality of materials and manufactured products. Then it is necessary to process the data affecting the obtained results and to introduce necessary changes and improvements of the processes. The OEE Operator system allows the connection to the machine controllers (PLCs) via the OPC standard. Therefore, thanks to the PLC it is possible to monitor and even control the machine and its operation from the level of the supervisory system (MES/OEE).

Monitoring of machine efficiency during operation

Monitoring of machines in the production plant by means of mobile devices enables many benefits for the customers. With our suite of functionalities, it is possible to monitor machine status and track the performance of production assets in real time. This allows you to know the status of your company’s machines anytime, anywhere without having to check or involve a third party. It is a significant simplification that allows to achieve higher productivity and efficiency of production processes. The main objective of the Operator OEE system (including Mobile OEE APP) is to increase the optimization and efficiency of machinery operation.

Monitoring of machines with Mobile OEE APP

The purpose of our Mobile OEE APP is to properly support production management in monitoring resources in order to increase productivity. By using PLC and OPC technology, it is possible to achieve the highest efficiency during operation. The moment a machine breaks down or stops working, a notification is sent. Which contains the relevant data, allowing you to get an answer about the causes related to the technical status. You will know the status of the machines by their color and description. In addition, you will also find the duration of each machine and information about the current production in progress as well as who is operating the machine.

OPC and PLC integration as effective support for business efficiency

A necessary element for acquiring meaningful data is the creation of appropriate optimization procedures. The most commonly used solution for standard data exchange in industrial enterprises is the OPC system. The aim is to improve configuration and integration and to complete tasks in significantly less time while reducing costs. This is why OPC UA has so many supporters among businesses.

OEE (Overall Equipment Effectiveness)

OEE (Overall Equipment Effectiveness) is a composite indicator designed to measure the performance of production assets and provide information about the entire production process, such as the performance of an assembly line. The term “effective productivity” is used to indicate that machines are being used more efficiently.

OEE is a composite indicator that reflects the efficiency of a plant. OEE consists of four components: availability, efficiency, quality, and productivity. These components can be measured by three indicators: availability rate (AR), performance rate (PR), and quality rate (QR).

OEE can be represented as follows:

OEE = AR × PR × QR

Why is OEE - Overall Equipment Effectiveness important?

OEE measures how efficiently machines, equipment, and labor are used to produce the product. When it comes to OEE, efficiency is one of the most important metrics. If you can increase your efficiency in any way, then it will have a big impact on your company’s bottom line.

Effective equipment is more profitable for manufacturers because they are paying less for maintenance costs and have increased production rates. Plus, they are requiring less of their workforce which means they have more time available for other tasks that will increase profits even further.

OPC Unified Architecture (OPC UA)

OPC Unified Architecture (OPC UA) is a communication protocol designed to enable different types of industrial devices to communicate with each other.

The basis of OPC UA is OPC Data Access (OPCDA) and Universal Architecture for Data Access (UDA). The former provides an abstraction layer for data to provide a unified view of data, while the latter provides a mechanism for transferring that data.

OPC Unified Architecture (OPC UA) is a communication protocol developed by the OPC Foundation that can be used for machine monitoring. This protocol uses different data formats to provide a universal way for machines and devices to communicate in a production environment. The goal of this protocol is to create an interoperability layer that allows communication between different types of equipment with minimal human intervention.

What are the different types of networks in OPC UA?

OPC UA is an open, scalable, secure industrial automation platform that facilitates the interoperability of plant floor operations. The OPC UA specification defines a set of common interfaces to synchronize industrial data between all levels of automation. It enables devices to communicate with one another across disparate networks, providing a single view of processes and equipment for operators and providers alike.

OPC UA provides all kinds of networks for different purposes. The following are the different types:

– Device networks – these are used to connect devices together in order to transfer data between them. They are typically low bandwidth networks that operate at speeds up to 1 Mbit/s

– Process networks – these are used communicate information about production processes between controllers and other control systems

– Device server network – this is used for installing

PLC (Programmable Logic Controller)

A PLC (Programmable Logic Controller) is an automated system that controls an industrial process through a physical interface. With this device, a person does not have to be around to do the work. It automatically manages production without the need for human interaction. One of the biggest advantages of using this type of system is that it speeds up production while giving people more time for other tasks within the company or organization. In addition to speeding up production, there are also various ways in which these systems can help your business improve the overall efficiency of producing goods or services.

The name Programmable Logic Controller comes from the fact that the controller consists of programmable logic in the form of code that is stored in its non-volatile memory. For an engineer or technician, a PLC is an essential tool for daily work. It provides safety, accuracy and efficiency for manufacturing plants.

How does PLC work?

Programmable logic controller (PLC) is a computerized device that control industrial processes in factories, power companies, water and sewage treatment plants.

The PLC is programmed to receive data from various sensors and use the data to determine the appropriate control action for a given situation. By programming instructions in advance, they can save time when compared to human decision-making.

Programmable logic controllers are widely used in industries like mining, food processing, pharmaceuticals and pulp & paper.

Machine monitoring and status

The use of machine monitoring allows to increase the efficiency of the production process, including minimizing downtime. All thanks to real-time machine status tracking.

Production lines have always been plagued by problems that interrupt flow and affect productivity, but now, with machine monitoring solutions, these problems can be detected and stopped before they turn into a larger-scale problem.

Machine monitoring allows you to monitor the status of all equipment connected to your system and is especially useful for those that are prone to failure, such as motors or valves.

Machine status monitoring tools are used in the manufacturing industry to improve production efficiency. Some of these tools include PLC and OEE.

PLC (Programmable Logic Controller) is a computerized system that controls the industrial process through data entry and gives feedback on the status of machines, among other things, minimizing downtime. OEE (Overall Equipment Effectiveness) is a yardstick that measures how well manufacturing equipment performs over a specified period of time. It analyzes the quality, performance and availability of production resources.

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