OEE (Mahabal)
Inflated manual OEE figures (76% vs. actual 59%) left real downtime and losses undetected. Velonex’s real-time monitoring exposed the gap and supported faster decisions.
Problem Statement
Mahabal needed to boost throughput and cut overheads within existing capacity, but unified tracking was hindered by 5 machines ranging from 1 to 10 years old with diverse CNC controllers like Mazatrol and Fanuc. Furthermore, manual OEE tracking concealed true operational losses by generating overly optimistic performance metrics that misled management. Without real-time visibility into machine downtime, the company could not systematically identify bottlenecks or make data-driven decisions to increase productivity.
Solution
Velodynamics deployed Velonex an Industry 4.0 monitoring system offering 24/7 OEE tracking and designed two hardware approaches (Siemens-PLC with HMI and TID via RS-232/Macro-B). To test the technology, Mahabal launched a pilot connecting three top-performing machines using the TID approach via LAN to a centralized computer. This setup delivered continuous real-time data to PCs, tablets, and mobile devices, empowering operators and managers to take immediate corrective actions on the shop floor.
Functionalities
Overall Equipment Effectiveness (OEE)
Tracks true productive manufacturing time, pinpoints underlying losses, and guides systematic process improvements.
Statistical Process Control (SPC)
Live performance monitoring that detects process shifts before non-conforming products or scrap are produced.
Product Traceability
Automated real-time tracking of product location, status, and availability across manufacturing stages via Barcode, QR Code, RFID, or Laser Engraving.
24/7 Remote Visibility
Real-time dashboards and analytics accessible anytime from PCs, tablets, or mobile devices across the globe.
Tech Stack
Layer
Technology Stack
Frontend
Angular
Backend
.Net core 8
Database
MSSQL
Cloud & Hosting
Amazon Web Services
Notifications & Services
Firebase Cloud Messaging (Mobile Application) / MessageHUB / SignalR
Impact on Client
Exposed True OEE
Within 9 months, Velonex revealed that the actual OEE was 59%, debunking the manual, overly optimistic estimate of 76%.
Immediate Capacity Recovery
Real-time alerts allowed fast, corrective actions on the shop floor, preventing critical loss of production hours
Minimized Waste & Cost
Shorter rework loops and reduced scrap directly reduced unit manufacturing costs and raised overall plant profitability.
Testimonials
"With Velonex, analyzing machine availability and shift downtime, including night shift performance, has never been easier. The ability to generate robust production and quality reports has streamlined our entire operation. Velodynamics’ technical expertise and dedication to excellence make Velonex an essential tool for modern production management."
Brahmanand Lad
Development Lead
ZP
February 2021
