Manufacturing / Plastics
Jeddah factory — OEE dashboard + retrofit in 90 days
Retrofitted 8 production lines with sensors + a live OEE dashboard. No line stop > 2 hours during installation.
- Duration
- 90 days
- Team
- 2 industrial engineers + 1 SCADA dev
- Location
- Jeddah, KSA
- Client
- Jeddah Manufacturing (under NDA)
The situation
Plant manager had no live visibility into line performance. End-of-shift paper reports lagged 24h. Mean time between failure data did not exist.
What we did
We tagged every line with vibration + amperage + cycle-count sensors. Routed signal through a Siemens S7 → Ignition gateway → PostgreSQL → Grafana stack. Trained the maintenance lead to read the dashboard in week 6.
The outcome
OEE jumped from estimated 58% to measured 73% within 8 weeks of go-live (measurement effect + targeted fixes). Maintenance team now reacts within 90s of a stoppage.
73%
OEE measured
90s
Time to react
8/8
Lines covered
Stack
Siemens S7 Ignition SCADA PostgreSQL Grafana
For the first time in 15 years, I know which line is bleeding before the shift ends.