MAJiK Systems

OEE & Production Monitoring

Find the capacity already sitting in your factory. Connected machine data turned into a live read on equipment effectiveness, production counts, and factory performance, so you can see what is running, what is not, and why.

11%

of revenue lost to unplanned downtime.

Most factories cannot see, in real time, which lines are running to plan and which are quietly bleeding output. You cannot fix what you cannot measure.

Source: Siemens / Senseye, The True Cost of Downtime 2024 (world's 500 largest companies)

Where your time goes

Total effective equipment performance (TEEP) for a typical 2-shift manufacturer.

17%
14%
9%
8%
4%
48%
Non-Operational Time Not scheduled for production.
Availability Loss Breakdowns, changeovers, and equipment failures.
External Losses Blocked or starved, waiting on upstream or downstream.
Performance Loss Slow cycles and micro-stops.
Quality Loss Scrap and rework.
Fully Productive Producing good parts at full speed.

Only 48% is fully productive. The other 52% is lost across five categories.

Understanding your losses by type and size is where optimization starts.

Most plants find 2 to 5 points of fully productive time in the first 90 days.

TEEP counts all available time, not just scheduled time. We optimize OEE, but we think bigger.

How It Works

From raw equipment signals to actionable intelligence.

1
Connect Equipment
MAJiK IoT Connect reads production counts, cycle times, and status signals directly from your PLCs. No manual entry, no clipboards.
2
Automatic OEE Calculation
Availability, performance, and quality calculated in real time from live data. Standard OEE or your custom formula.
3
Dashboards at Every Level
Overhead displays on the shop floor, equipment detail for engineers, factory views for managers, and enterprise rollups for leadership. One truth, every level.
4
Identify and Act
AI highlights top loss categories, trend anomalies, and improvement opportunities. Pareto charts generate automatically by shift.

Capabilities

What Visual Factory delivers for OEE & production monitoring.

Real-time OEE calculation (availability, performance, quality)
Automatic production counting with reject subtraction
Equipment status tracking (running, idle, faulted, changeover)
Multi-site comparison and benchmarking
Shift-over-shift trend analysis
Overhead display views for the shop floor

OEE gains come from acting on the losses you can finally see. AI for Continuous Improvement surfaces the root cause behind your top loss categories and turns the fix into digitized standard work. It is why we built MAJiK Visual Factory.

2-5 pt
More total productive time from downtime reduction alone.
Conservative across deployments; teams typically gain 2-5 points of total productive time from closing downtime losses before any other lever. On a line producing 1,000 units per producing shift, that is roughly 20 to 50 more units a shift.

MAJiK ROI research, 2026

See how manufacturers are improving OEE in the first 90 daysBuilt for CI Engineers & Plant Managers. See it live on your equipment.