From Downtime Blind Spots to Real-Time OEE Visibility: Ignition SCADA Across 15 Plants

Manufacturing | OT/SCADA | Digital Transformation

The Challenge

A diversified manufacturing group running 15 production plants had no unified system for tracking equipment performance in real time. OEE data was collected manually or through disconnected islands of automation, resulting in delayed reporting, inconsistent metrics, and an inability to act on losses during the shift. Leadership had no reliable mechanism to compare plant performance across the portfolio or identify systemic throughput issues.

Our Approach

• Designed and deployed Ignition SCADA stacks across all 15 plants, tailored to each site's existing PLC and MES architecture

• Built real-time OEE dashboards surfacing Availability, Performance, and Quality metrics at machine, line, and plant levels with shift-by-shift drill-down capability

• Coordinated system integration across multiple third-party integrators and on-site OT teams, maintaining a consistent data model across all deployments

• Implemented historian-backed trending to enable loss analysis and continuous improvement workflows at the plant level

Outcomes

• 15 plants live on a unified Ignition OEE platform within the program timeline

• Time-to-detect production loss events reduced from hours to under 5 minutes

• Cross-plant benchmarking enabled for the first time, revealing a 12–18% performance gap between top- and bottom-quartile facilities

• Manual OEE data entry eliminated at all 15 sites, saving an estimated 4–6 person-hours per plant per day

"Supervisors stopped chasing numbers and started managing performance — shift by shift, line by line."