Aptean Process Manufacturing OEE
From Insight to Output: How Process Manufacturers
For process manufacturers, nothing is more important than factory floor operations. Achieving optimal efficiency requires a clear, real-time understanding of how streamlined and productive your processes truly are.
By eliminating inaccuracies, proactively solving problems and creating informed plans for improvement, your organization can drive performance across departments and strengthen its bottom line. This kind of visibility supports daily decision-making and empowers teams to act with confidence and consistency.
Modern overall equipment effectiveness (OEE) systems unlock the visibility and control needed to drive meaningful improvements. While transformation takes commitment and collaboration, the shift to a modern OEE platform sets the stage for rapid wins and long-term success. With the right tools in place, your business can quickly gain momentum, boosting agility, enhancing profitability and empowering your teams to thrive.
Gain Real-Time Visibility to Eliminate Manual Processes
The implementation of a new OEE system affects every team in your business, which makes it essential to have a thoughtful plan for the transition. Once in place, the right solution simplifies responsibilities become clearer, data becomes more accessible and employees can immediately see how their actions affect performance.
Visibility into operational success or setbacks empowers teams to respond with speed and precision. Instead of relying on assumptions or delayed reports, manufacturers can act on real-time insights to maintain momentum, even when goals aren’t met. This clarity turns challenges into opportunities for improvement. Rob Hodgetts, Director of Operational Technology at Monogram Foods, explains what their production equipment effectiveness reporting looked like prior to their implementation of Aptean Process Manufacturing OEE, “We’d have to take some folks, lock them in a room with a big thick stack of papers, and then they would have to manually take that data—which may or may not be right—and type it into an Excel spreadsheet.”
These improvements are only possible when manual processes are replaced with automated, real-time tracking. An OEE system eliminates the need for paper records and spreadsheets, reducing human error and surfacing issues before they escalate. For example, without OEE, a manufacturer might miss early signs of viscosity inconsistencies, leading to batch rejections and costly rework. With OEE in place, those hold-ups are flagged immediately, allowing teams to take corrective action and protect output.
“Aptean
Process Manufacturing OEE has exceeded our expectations in that the visibility in the system is fantastic. This system has provided a great
return on investment through improved material variances and improved uptime.”
Rob Hodgetts, Director of Operational Technology,
Monogram Foods
Understand OEE and Why It Matters
OEE software for process manufacturers calculates your equipment’s efficiency using the OEE formula, providing you with real-time visibility into performance. It combines three factors into a single calculation:
OEE = Rate x Yield x Utilization
Rate = Units per minute vs. standard rate
Yield = Out/total processed in Utilization = Uptime/net available time
When performance drops below the 70% threshold, OEE software immediately alerts your teams enabling them to take corrective action before production slows. The system automatically calculates these factors and delivers accurate results in real time. This speed of insight prevents delays and ensures your decisions are based on facts.
By monitoring rate, yield and utilization continuously, an OEE system reveals bottlenecks and points of loss. With that knowledge, you can target improvements, streamline processes and give your teams the confidence that every adjustment they make is supported by reliable data.
Strengthen Plan Attainment to Protect Performance
Plan attainment measures how much of your production schedule is completed as planned. Missing these goals creates late orders and puts customer relationships at risk.
An OEE system keeps performance visible and measurable with up-to-date KPIs. Your teams know where progress stands and can act before issues expand. Meeting production goals consistently is critical for profitability. Aurora Organic Dairy, a leading dairy processor, faced challenges with production inefficiencies and rising operational costs. Without a modern OEE solution, the company wasn’t effectively analyzing downtime data resulting in its resin loss team losing $25,000 a month. Within eight months of implementing Aptean Process Manufacturing OEE, Aurora saved $200,000.
OEE also reveals the why behind your results. If you exceed your production plan, you know what drove the gain. If a shipment is delayed because an order takes longer to fill, you can trace the root cause.
Effective OEE platforms also monitor two areas where losses frequently occur:
› Changeover: Even a five-minute delay can affect plan attainment. By measuring changeover times, your teams become more aware of personal efficiency and can identify causes of extended downtime.
› Giveaway: Overfilling to meet unit or volume minimums may seem unavoidable, but tracking giveaway helps you minimize waste. This reduces material costs and mitigates legal risk from inaccurate packaging.
By addressing these areas proactively, you protect margins, safeguard compliance and maintain schedule integrity.
Equip Your Teams With the Right OEE Technology
Your plants are the foundation of your business, and your teams depend on accurate, timely information to perform at their best. Paper records and manual spreadsheets slow progress, add risk and make it harder to see where improvements are possible. A cloud-based OEE system replaces these inefficiencies with clear, actionable insights in real time.
Aptean Process Manufacturing OEE gives you visibility across every step, from batching through packaging. With our OEE software, you can measure key metrics such as plan attainment, units per man hour, changeover times and yield loss, all within one secure, cloud-based solution.
Our OEE is powered by AppCentral, Aptean’s purpose-built platform, it delivers industry-specific, preconnected applications embedded with AI to optimize end-to-end performance. This integration ensures centralized access to production insights, enabling seamless collaboration and faster decision-making across teams.
Designed specifically for process manufacturers, our solution tracks production losses, monitors labor use and helps reduce waste from overfilling or extended clean-in-progress cycles. With user-friendly design and built-in industry capabilities, implementation is straightforward, and your teams can begin realizing quality and productivity gains quickly.
at info@aptean.com or visit www.aptean.com.
About Aptean
Aptean is one of the world’s leading providers of purpose-built, industry-specific software that helps manufacturers and distributors effectively run and grow their businesses. With both cloud and on-premise deployment options, Aptean’s products, services and unmatched expertise help businesses of all sizes to be Ready for What’s Next, Now®. Aptean is headquartered in Alpharetta, Georgia and has offices in North America, Europe and Asia-Pacific.
To learn more about Aptean and the markets we serve, visit www.aptean.com.
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