OEE Software – How to Choose the Right Solution

Calculating OEE manually on a continuous basis involves tiresome effort. When comparing across time periods, products or locations, it quickly becomes difficult to keep track of everything. Fortunately, there are now many ways to calculate OEE automatically using machine data. One of these options is OEE software. To help you select the right software, we have summarized the most important considerations in this article. 

Tip: If you want to directly compare the top three providers, you can simply jump to the end of the article.

We compared these OEE software providers:

1. ENLYZE
   Calculates OEE from machine data with access to all process data, thereby enabling root cause analysis and OEE improvement. As a best-in-class solution, it can be easily used and customized by the shop floor.

2. OEE.AI
   Calculates OEE using retrofitted sensors without comprehensive integration of process parameters. This makes it quickly ready for use, however, no root cause analysis using process data is possible.

2. MPDV Hydra

Offers comparable OEE functions, but with an extremely long implementation time and high costs. Adjustments cannot be made by the shop floor but only by IT, which often takes months to years.

OEE tracking software – you must pay attention to these 6 criteria

In the German-speaking market alone, there is now a large range of OEE software available. However, these solutions differ so greatly that a comparison of OEE software is only possible with a significant investment of time. Therefore, we have created a catalog based on six criteria that may help you with your selection:

1. Functionality

2. Future-proofing

3. Integration into existing systems

4. User-friendliness and available training

5. Support

6. Implementation duration and price

You can easily download this catalog on OEE software criteria as an Excel file. If this is too complex for you, feel free to book a 30-minute consultation call with our team to find a solution together.

Good to know: Excel is an example of a free OEE software. Although it does not incur any additional costs, you pay with your time and missed optimization opportunities – we therefore recommend avoiding this approach.

1. Functionality: Does the OEE software fit the needs of my plant?

The first question is self-explanatory: Does the tool have the appropriate functions so that the ROI calculation for the OEE software delivers a satisfactory result? To find this out, you should ask yourself these questions:

Is the solution suitable for my manufacturing process? 

There are different requirements for an OEE software – depending on whether products

• are manufactured discontinuously (e.g. CNC, injection molding),

• are created as part of a batch manufacturing process (e.g. rubber production, dough production) 

• or are manufactured continuously (e.g. extrusion).

In a first step, you should therefore look at what types of processes you have. This provides the foundation for carrying out the OEE calculation for continuous processes.

Are OEE and its components (availability, performance, quality) calculated separately and can they be analyzed individually? 

Usually, the reason for purchasing OEE software is the desire for a higher OEE. However, you can only improve OEE if you can analyze the individual components in detail – and thus determine where the greatest leverage for improvement lies.

Can OEE be calculated at the relevant levels of aggregation?

Ideally, you should cover all detail levels in your OEE calculation, such as the location, the analysis of individual assets, and their production orders. This allows you to perform the entire analysis within one software and derive the correct measures within a few hours.

Can loss catalogs for availability, performance, and quality be created to systematically record losses?

To ensure that people in the plant do not work in isolation and name things differently, there should be a uniform database. However, you can only achieve this if you can define a catalog of losses in advance, from which operators can choose.

Why is this important? If all stakeholders categorize losses consistently, you can compare them over time periods and assets. Additionally, operators save time because recording using catalogs is faster.

Is the data available live for analysis in order to react proactively to problems?

If, for example, there is a prolonged machine downtime, action should be taken immediately to prevent further losses. However, this is only possible with real-time data visualized in a clear OEE dashboard.

Are there functions for the root cause analysis of production failures? 

Ideally, these functions should be based on the established framework of the 6 Big Losses of shop floor optimization. This model enables a structured categorization of typical loss types in production – such as breakdowns, setup times, minor stops, or quality defects – and thus creates the basis for a systematic root cause analysis to optimize the manufacturing process in the long term.

Does ENLYZE offer these functions?

ENLYZE includes all of these functions. But: Our solution is specifically suited for continuous processes – discrete manufacturing is only covered to a limited extent.

2. Future-proofing: Can the OEE software grow with your requirements?

Calculating OEE for a few similar assets is easy. This is exactly what many OEE software providers can do very well and cost-effectively.

But most production operations want to do more than just calculate OEE; they also want to:

• understand and eliminate the root causes of downtimes, performance losses, and quality problems.

• connect multiple sites, some with older machinery.

• use machine data for other purposes, such as product traceability or energy optimization.

However, most tools are limited to calculating OEE – but calculation alone does not help anyone. Therefore, you should consider your future requirements when making your choice.

How easy is it to roll out the solution to additional machines?

It is best to ask for concrete examples from customers who started small and are now using the product on a large scale. Can you speak with these customers to hear about their experiences first-hand?

Is OEE captured at the order, machine, and location level?

Many solutions do not cover all three levels of detail, making use across different locations impractical.

Can the system be configured by production, or is IT or an external service provider required?

In order to adapt the tool perfectly to your requirements, minor adjustments are almost always necessary. Your production team should be able to implement these adjustments without expensive consulting or lengthy IT tickets.

Is ENLYZE equipped for my future requirements?

In short: yes. ENLYZE not only calculates OEE but also enables detailed root cause analysis based on machine data. In addition to OEE, you can use the captured machine data for traceability or production monitoring, or analyze the data in tools like PowerBI and Minitab. Thus, ENLYZE always grows with your requirements and helps you recognize trends in machine data.

3. Compatibility: Does the OEE software speak to my existing equipment and systems?

What no one needs is a digitalization solution that is incompatible with existing systems. Because then, the manual effort remains high and the benefits limited.

Ask these questions to find out more about the compatibility of the OEE software:

How is the data collected to calculate OEE?

To calculate OEE, data on downtimes, product-based performance, and scrap is required. Every software will capture this data, but the question is: how?

Our recommendation: As far as possible, this data should be recorded automatically based on machine data. This is the only way to ensure data is available in real-time (proactive action), is free from errors, and accurately reflects what is happening on the shop floor. The good news: capturing OEE automatically instead of manually increases productivity. 

Does the OEE software offer connectors for all data sources, or do additional providers have to translate the protocols to OPC UA and the like?

Here you should consider which data sources will be relevant for the OEE calculation now and in the future. If the OEE software cannot capture these data sources, costs and effort for connectivity services will arise. A dependency on many different providers can quickly develop.

Can product and order information also be captured and processed? 

OEE can only be calculated accurately when process data is linked with the respective order and product. And this is the only way you can detect "problematic products" and product-related issues. Ideally, the OEE software integrates directly with your ERP and MES systems to write this data back into these systems.

Are there open and documented interfaces to use the data in other systems as well? Can the data be exported?

The data you collect for OEE calculation is also relevant for numerous other use cases (traceability, production monitoring, controlling, etc.). 

If the OEE software offers open interfaces and data exports, it can grow with your requirements in the future. Without these options, data must be recollected for new use cases – resulting in expensive, isolated software silos.

How ENLYZE integrates with your systems

Within one week, we integrate ENLYZE with ERP and MES to link product and order data with machine data – thus calculating an accurate OEE.

Thanks to open interfaces and data export, you can also work with your data in other systems like PowerBI, Grafana, Minitab, and more.

4. User-friendliness: Will your team use the OEE software daily?

The OEE software is only worth what your employees make of it. The best software won't move you forward if it is so complicated that nobody uses it.

Regarding user-friendliness, you should pay attention to the following:

Is the user interface intuitive and easy to understand? 

Can the provider give you trial access so you can try out the tool? This is the only way to see how easy the OEE software is to use.

Are training sessions or tutorials provided?

Find out how your team will be trained and what materials (articles, videos, etc.) are available for self-guided learning.

Is the solution accessible on mobile devices or only on HMIs?

In most cases, the most flexible solution is a browser-based app, which can be securely used from any device with internet access.

Is ENLYZE user-friendly?

Of course, we are biased. But we would claim to offer one of the most user-friendly OEE tools on the market. The best way to see this is in our interactive product tour, which works on desktop devices.

In addition, we train your employees at the beginning and provide detailed help materials explaining various functions.

5. Support & Maintenance: What if problems arise with the OEE software?

If problems occur with the software, a solution should be found quickly. You should also ensure that the software is regularly updated, for example to patch security vulnerabilities.

Here is what you should look out for:

What types of support are offered?

There are various options, such as by phone, email, chat, or directly on-site. Even more importantly: how quickly are your issues resolved?

Are there Service Level Agreements (SLAs)?

Anyone can claim to offer good support. With Service Level Agreements, the terms are contractually defined, legally securing the quality of support for you.

How are software updates and maintenance notices provided?

Is it a SaaS software that continuously evolves, or a one-time purchased software where every subsequent update and support package must be purchased separately?

How do support and maintenance work at ENLYZE?

At ENLYZE, we let our customers choose. Some prefer close support, while others like to work independently using our documentation. New features are developed several times a year and do not require additional payment.

6. Implementation and Price: How much does the OEE software cost and how quickly can you work with it?

We deliberately address cost and implementation aspects last. If you only look at the price, you might end up with a solution that offers no added value. Thus, even the cheapest and fastest tool is a pure waste of money.

When it comes to implementation and costs, you should pay attention to the following:

How long does it take until the tool is ready for use?

Ideally, sales representatives should transparently explain how long the implementation and commissioning take. Examples of similar customers are particularly helpful, as they realistically reflect the effort and provide guidance.

What are the total costs? 

Perform a thorough cost analysis, including license fees, implementation costs, integration costs, hardware costs, training fees, and ongoing maintenance costs. Especially when additional connectivity solutions are required, both licensing and integration costs rise.

How do costs scale with more users, data sources, and functions?

Software is often associated with low entry prices. However, caution is advised here: even in 2–3 years, as the usage and complexity of the solution increase, the costs must still make economic sense. Therefore, think one step ahead and plan for the potential costs of a larger roll-out.

How much does ENLYZE cost and how long does the implementation take?

The costs depend on the number of connected production assets. You pay a fixed price for the use of our solution as well as a variable price based on the number of assets. The implementation of ENLYZE takes less than two weeks.

Find the right OEE software now and benefit from greater efficiency 

Choosing the right OEE software is a crucial step towards greater transparency, efficiency, and digitalization in production. When you compare different solutions, you lay the foundation for sustainable improvements on the shop floor. Especially with long-term investments, a close look at functional scope, scalability, and user-friendliness is worthwhile. This turns a complex selection of OEE software into a targeted decision-making process – which quickly pays off.