Shopfloor Copilot is an OEE monitoring software that delivers real-time Availability, Performance, and Quality metrics per production line and station — all on-premise, with no cloud dependency, directly from your OPC UA-connected machines.
OEE (Overall Equipment Effectiveness) is the gold standard KPI for measuring manufacturing productivity. It combines three factors:
OEE = Availability × Performance × Quality. World-class manufacturers target OEE ≥ 85%. The global average in discrete manufacturing is approximately 60–65%.
OEE monitoring software automates this calculation in real time, replacing manual spreadsheets and paper logbooks with live dashboards that surface losses the moment they occur.
Shopfloor Copilot's OEE monitoring module connects directly to your machines via OPC UA (the industrial standard for machine connectivity). Raw PLC signals are mapped to OEE components through the built-in Semantic Signal Engine — no manual data entry, no custom integration work per machine type.
Per-line and per-station OEE cards with color-coded status. Refresh interval configurable. Shift and hourly aggregations available.
Every unplanned stop is logged with timestamp, duration, and automatic loss category classification (planned, unplanned, speed loss, quality loss).
Day-over-day and shift-over-shift OEE trends. Identify recurring loss patterns by station, line, or shift.
Live Andon board shows station × line OEE status: Green ≥85%, Amber 50–84%, Red <50%. One-click alert acknowledgment.
Drill-down from OEE metric to contributing downtime events. Pareto charts for loss categories by line and time period.
Auto-generated shift OEE summaries included in digital shift handover. Incoming shift receives pre-populated context on line performance.
Shopfloor Copilot uses the IEC 62264-compliant OEE formula:
Raw OPC UA signals are mapped to these components via the YAML-based Semantic Engine. A signal declaring type: availability_loss is automatically counted as downtime. No hardcoding per machine model.
Most cloud-based OEE tools require your production data to leave your factory floor. For manufacturers in automotive, aerospace, pharmaceutical, and defence sectors, this creates data sovereignty and compliance challenges.
Shopfloor Copilot stores all OEE data in a local PostgreSQL 16 database on your own server. No OEE data is transmitted to external servers. Your competitors cannot access your production efficiency data. Your OT network remains isolated.
Understanding where your OEE stands relative to industry benchmarks:
A 10-percentage-point OEE improvement on a production line running 2,000 hours/year at €500/hour translates to €1,000,000 in additional throughput — without purchasing new machinery.
OEE monitoring software tracks Overall Equipment Effectiveness — a composite KPI measuring Availability, Performance, and Quality for manufacturing equipment. It collects data from machines (via OPC UA, MQTT, or manual entry) and calculates OEE in real time, showing operators and managers where production losses occur.
Shopfloor Copilot connects to PLCs and machines via OPC UA. The built-in semantic engine maps OPC UA nodes to OEE signal types (run/stop state, cycle count, reject count). No custom middleware or per-machine setup is required beyond the initial YAML signal mapping file.
Yes. Shopfloor Copilot is 100% on-premise. All OEE data is collected, stored, and displayed within your factory network. No internet connection is required after initial deployment. Suitable for air-gapped environments.
Default thresholds: Green ≥85% (world-class), Amber 50–84% (improvement needed), Red <50% (critical action required). All thresholds are configurable per station type and production line.
Request a live demo with simulated production data across 3 lines and 24 stations. See real-time OEE dashboards, downtime event capture, and Andon board alerts — all running locally in your browser.
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