Optimize Production & OEE with iNut: Availability, Performance, Quality on One Dashboard

At many factories, a seemingly simple question — "what percentage of capacity did the line run at today?" — has no accurate answer. Output is logged by hand at the end of the shift, downtime is estimated from memory, and quality defects get lumped together — the data is late, fragmented, and unreliable. By the time an underperforming machine is spotted, a whole week of output has already slipped by.

OEE (Overall Equipment Effectiveness) is the most concise measure of a production line's health: Availability × Performance × Quality. But OEE is only valuable when measured automatically, continuously, and in real time — which is exactly what iNut was built to do: plug into existing machines, gather signals, calculate the metric, and display the answer instantly on screen.

Accurate OEE starts with accurate data. Instead of manual logging, iNut takes signals directly from the line: the machine's run/stop status, counted output, cycle time, plus dedicated sensors for current, vibration, temperature, compressed air, and photoelectric counting. Every few-second stoppage, every defective part — the system records it all, without missing a beat.

Factories are rarely a single brand: a Siemens PLC next to a Mitsubishi inverter, older machines with nothing but indicator lights. iNut brings it all together. iNut OPC talks to PLCs over OPC UA / Modbus / XML-DA; iNut RS485 and WiFi Mesh pull signals from hard-to-wire corners of the plant, even running on solar power in outdoor areas. No need to replace machines — just add a connection so they can "speak".

iNut PC sits at the edge layer right on the shop floor: gathering data and running the logic to calculate Availability (actual run time / planned time), Performance (actual output / theoretical output), and Quality (good units / total units). The three figures multiply into OEE, updated every minute — along with an analysis of the Six Big Losses (breakdowns, changeovers, minor stops, reduced speed, defects, rework) so you know exactly where time is going.

The most expensive loss is the one detected too late. When a machine stops for too long, the cycle rate drops below threshold, or the defect rate spikes, iNut pushes an alert instantly via Email/Telegram to the right person — the line leader, maintenance, or shift manager. It's a digital andon: the phone buzzes before the red light even turns on, cutting response time from a shift to seconds.

iNut Platform (self-hosted cloud) builds a real-time SCADA dashboard: OEE by machine, by line, by shift; a Pareto chart of losses; hourly/daily/weekly trends. On the iNut app, managers view metrics and receive alerts anytime, anywhere. Management no longer has to wait for the end-of-month report — the numbers show up as the work is happening.

No need to stop the line to "upgrade." iNut is added as an overlay layer: plug iNut OPC/RS485 into existing PLCs and sensors, place iNut PC as the edge device in the electrical cabinet, use WiFi Mesh to cover hard-to-wire areas and 4G uplink where there's no LAN. Add iNut Datalogger if you need long-term on-site storage. Start with one key machine, get measuring immediately, then scale out across the whole factory.

// Quick specs