OEE for high-speed lines that stop thousands of times a month.
Converters lose time a few seconds at a time: a jam, a weak weld, a roll change, a handover that runs long. Standard OEE blends all of it into one Performance figure. Augos Factory counts every halt, ranks the repeat faults by owner and measures every planned stop against its standard.
- Interruptions11,944 events · operator59.6 h
- Planned stops314 events · planning and operator58.6 h
- Unplanned stops358 events · technician54.9 h
- Speed and quality lossspeed 11.8 h · quality 15.6 h27.4 h
Converting lines fail in patterns.
High cycle rates, a handful of wear parts and frequent material changes give these lines a loss profile of their own. Each pattern has a measurement that names its owner.
Interruptions on a fast machine.
The Augos Operator Terminal counts every pulse and times the gap between them in milliseconds, so they stop hiding inside the Performance figure. Duration was near-identical for every operator, 17.1 to 18.5 seconds. The count was not, which is where coaching starts.
The repeat mechanical fault.
A sealing fault stopped the line another 22 times for 9.4 hours. Ranked by owner, these are a maintenance plan and a spares question, and the ranking says which one to fix first.
Shift changes against a standard.
Roll changes were disciplined: 147 of 172 inside their standard. Shift changes were not, and only one landed inside it. When nearly everyone misses a standard, the standard is the question, and the platform shows that before anyone is blamed.
The gap to your own best operator.
The two busiest operators cleared the same product's stops in 8.2 and 12.0 minutes on average. The Best Operator Benchmark builds the gap from times a colleague has already achieved.
Augos platform, one anonymised plastic converting line, one month in 2026. Standards are the site's own settings.
See how many of your line's hours were seconds. A 30-minute call with a manufacturing specialist, using one of your lines as the example.
Standard OEE shows the loss. OEE+ shows who owns it.
The OEE arithmetic stays standard. One column is added, and the fix follows the owner.
- Stoppage analysis: Planned stops, unplanned stops and interruptions counted separately and ranked by owner. How stops are classified
- The Owner column: operator, technician, planning, quality, external and shared. How it works
- One sensor, one terminal, no PLC: a sealed IP67 pulse sensor at the bottleneck and the IP65 Augos Operator Terminal. The terminal
- Augos Assist (Response): splits a repeat fault into operator evaluation and resolution, technician response time, and active and inactive wrench time. Augos Assist
What it costs, and what you get.
One offer covers every line. The monthly fee includes every capability except the metrics that need Augos Assist, an optional extra.
R19,500 once per line for deployment, ex VAT.
Several lines? The price per line falls. We agree it with you in conversation.
Book a demoThe first 90 days cannot be cancelled. After that, one calendar month's notice, and the hardware comes back to Augos.
The monthly fee includes
- Every capability, except the metrics that need Augos Assist
- The Augos Operator Terminal and pulse sensor, owned by Augos
- A SIM supplied by Augos, so there is no network or IT project
- A free terminal replacement every 36 months, and a one-year warranty
The once-off fee covers
- Set-up and remote testing
- Two days of on-site operator training
- Four weekly one-hour data reviews
- Leadership training on the platform
Travel and subsistence for on-site training are not included.
What you provide
A power point at the line. Your own people mount and connect the terminal, with our guidance.
Optional extras, per month, ex VAT
- Augos Assist: R250 per technician, or R1,250 for the whole site
- Public Display: R300 per display, or R1,500 for the whole site
Converting and packing lines on Augos.
Anonymised. Every figure traces back to the platform.
What monitoring reveals when you leave it running
One line, watched continuously for four months. Planned downtime took a third of its time, and the trend kept surfacing slow drifts a one-off audit would miss.
Read the case study → Packaging and bags · Bag manufacturerThree shifts, one live board
A three-shift bag maker tracked output on paper, one number per shift. Demand was rising and nobody could say whether the machines had headroom. A live record of every stop answered it with data.
Read the case study → Hygiene products · Hygiene products manufacturerSpotting a failing component before it broke
Total downtime on the line looked flat. Underneath, one cutting unit's mechanical losses rose 440% in five months, the signature of a component nearing end of life.
Read the case study →Energy per kilogram, with the base load and the variable load separated: resource intensity.
Common questions.
Our line runs fast but never seems to produce. Why?
Usually interruptions, what standard OEE calls minor stops or micro-stops. On one anonymised converting line, over one month in 2026, the sensor counted 11,944 Interruptions averaging eighteen seconds: 59.6 hours, more than all the declared breakdowns put together, and none of them in a manual log. Standard OEE hides them inside the Performance figure as slow running.
Is the loss the machine or the operator?
The Owner column answers it per fault. On that line 94% of declared unplanned time was mechanical, led by one forming-station fault that stopped the line 107 times. Interruption duration was near-identical across operators (17.1 to 18.5 seconds), so duration was the machine's; the count followed who was running it.
How do you measure shift changes and roll changes?
Each planned task has a Standard Allowed Time. On the same line 147 of 172 roll changes finished inside their standard, while shift changes ran 22.8 hours against a 4.4-hour allowance. The platform reports the overrun as Operator Compliance loss and the scheduled time as Planning Efficiency Loss, so the plant can tell a behaviour problem from a standard that no longer matches the handover.
Do you connect to the converting machine's controls?
No. A sealed pulse sensor counts output at the bottleneck and the Augos Operator Terminal captures stops and reasons, so the system goes onto any machine, old or new, with nothing wired into the PLC.
Can we measure electricity per kilogram processed?
Augos Energy meters electricity, compressed air and other utilities at the same sites, so energy can be read against production per half hour. Plastics processing is a fixed-plus-variable load: a base load the plant pays whether or not it runs, plus kWh per kilogram processed. Measuring both is what makes a per-unit figure honest.
See how many of the month's hours were seconds, on one converting line.
A 30-minute call with a manufacturing specialist. We look at one converting line together and show you where its hours went, and who can get them back.
- Live within 48 hours of your kit arriving
- One sensor, one terminal, no PLC and nothing to integrate
- R4,950 per line per month, ex VAT. 90 days, then a month's notice