Realtime OEE calculation powered by IoT sensors, straight from your production line.
Karsatech OEE Realtime computes Availability, Performance, and Quality automatically from machine data via IoT. Detect losses faster, identify shift bottlenecks, and make production decisions based on what is actually happening on the factory floor.
OEE dashboard preview
Built for production line transparency
More than an end-of-shift OEE number. The platform unifies machine connectivity, realtime calculation, and ready-to-use visualization for operations teams.
Direct connection to machines
IoT sensors read running status, actual speed, and reject counts without manual operator input.
Consistent OEE calculation
Availability x Performance x Quality is computed automatically with configurable time windows per shift.
Insights that are ready to act on
Biggest losses, lagging lines, and quality issues surface automatically so teams no longer need manual recap.
Realtime OEE - Line A
Availability, Performance, Quality, and OEE calculated live from IoT sensors.
Availability
Performance
Quality
OEE
Line A - Shift 1
Performance drop detected
Line B dropped 8% in the last 10 minutes - check material feed.
Why realtime OEE is different from manual OEE reports
Weekly OEE reports only tell you what already happened. Realtime OEE tells you what is happening right now and what to do about it.
Loss is visible while it is happening
Downtime, slow cycles, and rejects appear on the dashboard immediately so the team can act in the same shift, not next month report.
Machine data, not operator opinion
IoT sensors remove manual input errors and make OEE numbers comparable across shifts, lines, and plants.
A more honest decision baseline
Bottleneck capacity, products with the highest loss, and the most efficient shift are identified from runtime data, not spreadsheets.
Core features of OEE Realtime + IoT
This marketing page follows product capabilities already connected to IoT sensors, so the message stays aligned with real factory implementation.
IoT sensor connectivity
Receive data from PLCs, production counters, and quality sensors through an IoT gateway that supports common industrial protocols.
- Multi-protocol sensor input
- Ready-to-use edge gateway
- Auto-reconnect on link loss
- Local buffering when offline
Realtime OEE calculation
Availability, Performance, and Quality are computed automatically from machine data using configurable time windows per shift.
- Global standard OEE formula
- Per shift and per line window
- Auto loss categorization (downtime, speed, quality)
- Per-minute OEE history
Visual OEE dashboard
Monitor OEE across lines and shifts in a single view. Spot trends and outliers without building manual reports.
- Live tiles per line
- OEE trend chart
- Pareto of biggest losses
- Cross-shift comparison
Automatic downtime detection
The system recognizes downtime patterns, classifies the type, and notifies the responsible team while the event is still ongoing.
- Auto-classify downtime
- Notify accountable team
- Simple root cause tagging
- Loss duration and frequency
Alerts and notifications
Configure OEE thresholds per line. When OEE drops below the threshold, operations teams receive alerts via the dashboard and the channel of choice.
- Threshold per line
- Realtime notifications
- Multi-channel alerts
- Tiered escalation
Export and data integration
OEE and loss data can be exported or connected to existing systems (ERP, BI, data warehouse) for deeper analysis.
- CSV export and API
- ERP and BI integration
- Long-term data historization
- Sample dashboard look-up
How OEE Realtime flows from sensor to decision
This flow shows how a signal on a machine becomes actionable insight for your operations team.
IoT sensors and gateway
Install sensors on machines, connect to PLCs or counters, and stream data through a Karsatech-prepared gateway.
Stream data to the platform
Machine status, cycle time, and reject data are sent to the OEE platform in realtime with local buffering when the network is unstable.
Compute OEE automatically
The platform calculates Availability, Performance, and Quality using your shift configuration, target speed, and quality standards.
Insight and alerts for the team
The dashboard surfaces current OEE, alerts fire on significant loss, and the team can act in the same shift.
A strong fit for plants that want runtime-data decisions
OEE Realtime is most relevant for production facilities that already have machines and want to remove blind spots between the shop floor and management.
Discrete and assembly manufacturing
Measure assembly line efficiency, bottleneck capacity, and loss contribution of each production stage.
Operations and continuous improvement teams
Provides consistent OEE data for lean, Six Sigma, and long-term OEE improvement programs.
Plants with many lines and shifts
Standardize OEE measurement across lines and shifts so comparisons are apples-to-apples.
Multi-plant manufacturing groups
Consolidate OEE across factories in one platform for better benchmarking and capacity allocation.
Two packages for different OEE needs
This first stage offers two implementation paths so plants can start with the scope that fits and grow as data needs expand.
Starter
Package for plants that want to start measuring OEE on a single primary line with IoT sensors and a standard dashboard.
- Up to 1 production line
- Basic IoT sensors and gateway
- Standard OEE dashboard
- Basic threshold alerts
- 30-day OEE history
Enterprise
Package for organizations that need multi-line coverage, ERP integration, and more granular alerts across shifts.
- Multi-line and multi-plant
- Industrial-grade IoT gateway
- Custom dashboards and API access
- Multi-channel alerts and escalation
- ERP and BI integration
- Long-term data history
Implementation scope and commercial terms are tailored to the number of lines, sensor types, and existing system integration requirements.
Move OEE decisions from spreadsheets to runtime data.
Start with a short discussion about your production lines, the machines already in place, and the OEE improvement target you want to reach.