A chocolate manufacturing company digitalizes its packaging lines for automated OEE monitoring. To achieve this, the company is implementing an integrated IoT solution that recorded precise machine data, enabling well-informed decision-making. The modular architecture allows for flexible expansion and opens up new potential for other industries as well.
The IoT expert and co-developer of this solution is Perinet GmbH, which implements an end-to-end infrastructure from the field level to IT (including the cloud) based on standards. This allows for direct, smart, and secure integration of sensors and actuators with the cloud, the internet, and company IT.
The challenge: Unknown efficiency of the packaging machines
A medium-sized chocolate manufacturing company wants to optimize its production and is therefore equipping its packaging lines with real-time OEE monitoring. OEE stands for “Overall Equipment Effectiveness.” This key figure shows companies how efficiently their production systems are operating. OEE is calculated as the product of availability, performance, and quality, expressed as a percentage.
OEE = Availability × Performance × Quality
- Availability measures how often and for how long a machine is actually available for production.
- Performance evaluates whether the machine reaches and maintains its optimal operating speed.
- Quality indicates how many of the produced units are free of defects.
A value of 100 percent means that a system operates continuously, at maximum speed, and without producing any defects. OEE monitoring offers clear advantages:
- First, the OEE value helps identify production losses by revealing the causes of downtime, slow processes, or quality issues.
- Second, it supports targeted process improvement by precisely identifying weak points.
- Third, consistent use of OEE leads to cost savings by reducing downtime, increasing productivity, and minimizing waste.
Lack of transparency in production problems
Through OEE monitoring, companies gain reliable key figures for strategic decision-making. This allows them to optimize all production systems in the long term and strengthen the company’s competitiveness. If the individual OEE values are not determined precisely enough, opportunities for improvement in the production process remain undetected. To address this, it was necessary to digitalize the relevant machines. Automated collection of the base values for OEE over an extended period makes it possible to gather sufficient data.
Challenges at a Glance
- Lack of real-time data hinders root cause analysis
- Imprecise metrics prevent process improvements
- Hidden downtimes reduce utilization
- High effort for retrospective data collection
The Solution: IoT-based Real-Time OEE Monitoring
The company commissioned Perinet and Zentinel MDS to develop a custom IoT solution tailored to the production line. The digital OEE monitoring system captures machine signals in real time, including production speed, the number of defect-free and defective units, as well as operating and downtime periods. Intuitive dashboards visualize key metrics, while detailed reports provide targeted analysis.
Modular design with industrial components
The IoT system combines an IoT adapter, an edge server, and Single Pair Ethernet (SPE). The architecture is designed to be scalable, so additional machines or sensors can be easily integrated, even as production volumes grow.
The ZentNodeOEE adapter is specifically developed for automatic data collection in industrial environments. It monitors critical performance indicators such as produced units, scrap rates, availability, and downtimes without interfering with existing machine control systems.
The ZentEdge server is a robust edge computer that collects, stores, and processes machine data from ZentNode. The data is stored in the SQL database of ZentEdge and made accessible to your existing systems via standard IT protocols. ZentEdge serves as a bridge between operational technology (OT) and information technology (IT).
Single Pair Ethernet (SPE) handles communication between the individual components. It enables data transmission at 100 Mbps and power supply through a single cable, significantly reducing installation effort. SPE eliminates the need for complex gateways and allows the integration of industrial devices into IT networks using standard protocols such as HTTPS and MQTT, or via a REST API. All data transmission is additionally secured using mTLS certificates.
Transparent processes and new application areas
With the new OEE monitoring system, the manufacturer gains immediate transparency into the condition of its packaging lines. The collected data enables a well-founded, long-term analysis for continuous process improvement. Decision-makers can now respond directly to the causes of performance losses and take preventive action at an early stage.
The system requires no modifications to the machine control. Its modular structure allows it to be easily expanded to additional machines and systems. This flexibility supports a gradual digitalization process tailored to a company’s specific conditions. As a result, the OEE monitoring system is suitable for a wide range of industrial applications:
- Consumer goods manufacturing
- Textile and paper processing
- Logistics centers
- Electronics
- Plastics production
In all these areas, continuous OEE monitoring provides valuable insights into the actual performance of equipment. The system helps make processes transparent and establishes a solid foundation for data-driven decision-making.
The result: improved decision-making through OEE
Implementing OEE monitoring marks an important step toward data-driven, continuously optimized production. The IoT solution demonstrates how digital value can be created with minimal intervention in existing structures. The system enables precise recording and analysis of key metrics such as availability, performance, and quality. Clear visualization of production data helps decision-makers respond effectively and implement lasting improvements.
Summary of results
- Data-driven response to performance losses
- Targeted improvement of packaging lines
- IoT solution operates without interfering with machine control
- System easily expandable to new machines
