5-Point OEE ImprovementWithout Buying New Equipment
Eliminate the Six Big Losses. Turn 70% OEE into 75%. Add €2-4M in productive capacity per line.
90-day results • €2.4M recovered in real client case • No CapEx required
Trusted by precision manufacturers improving from 68-72% OEE to world-class performance
Every Percentage Point of OEE Is Worth Millions
OEE (Overall Equipment Effectiveness) measures how well your manufacturing equipment performs relative to its maximum potential. It combines three factors: Availability (uptime), Performance (speed), and Quality (good parts). An OEE of 70% means you're only getting 70% of your equipment's potential output.
The gap between your current OEE and world-class 85% represents lost revenue you'll never recover. Unless you systematically eliminate the Six Big Losses.
Availability Losses
- • Equipment Failures
- • Setup & Changeovers
Performance Losses
- • Small Stops & Idling
- • Reduced Speed
Quality Losses
- • Startup Defects
- • Production Defects
PrismaWerk delivers precision analytics that identify and eliminate your highest-impact losses. We analyze equipment sensor data, process logs, and production schedules to pinpoint which of the Six Big Losses is bleeding your productivity most—then systematically attack it.
Target Result: 5-point OEE improvement within 90 days. Predictive maintenance that eliminates Equipment Failures. Constraint optimization that fixes Performance bottlenecks. Automated quality control that detects defects and pinpoints the root cause. All using data you're already collecting.
€2-4M annual value per production line
Validated methodology impact from 5-point OEE improvement (e.g., 70% → 75%)
Recognizing the Losses That Kill OEE
If any of these sound familiar, you're leaving millions on the table
Your OEE Is Stuck Below 75%
Equipment Failures killing Availability. Micro-stops destroying Performance. Defects bleeding Quality. Every point below world-class 85% is lost revenue you'll never recover.
You Can't See Which Loss Is Costing Most
Is it unplanned downtime? Reduced speed? Setup time? Defects? Without data-driven diagnosis of the Six Big Losses, you're guessing where to improve—and guessing costs millions.
Reactive Maintenance Destroys Availability
Equipment failures you could have predicted 7-14 days early. Unplanned downtime costing €50K+ per incident. Your Availability score bleeding while you react instead of prevent.
Hidden Performance Losses Throttle Output
Lines running at 80% of nameplate speed. Micro-stoppages stealing 2-3 hours daily. Bottlenecks you can't identify in your dashboards. Your Performance score should be 95%+—not 75%.
Why Production Leaders Choose PrismaWerk
OEE optimization built on TPM methodology and real-world manufacturing expertise
TPM Methodology, Not Just Tech
Availability, Performance, and Quality are dissected using TPM methodology. The system speaks MTBF, MTTR, TEEP, and Six Big Losses—because that's the language of world-class fabs producing €500M+ annually.
Identify Your Costliest Loss First
Not every OEE loss is equal. The data quantifies which of the Six Big Losses is bleeding productivity most, enabling systematic elimination. Data-driven prioritization replaces guesswork.
90-Day OEE Gains, Not 2-Year Projects
Measurable OEE improvement in 90 days with pilot projects starting at €45K. Prove ROI before scaling across the facility. No multi-year 'digital transformation' limbo.
Results Measured in OEE Points
Success is reported in Availability %, Performance %, and Quality %—not abstract 'model accuracy.' The only metric that matters is OEE improvement. Real client impact: 5-point gain = €2-4M per line.
5-Point OEE Improvement × €2-4M Per Line = ROI You Can Take to the Bank
How We Eliminate the Six Big Losses
Systematic approach to improving Availability, Performance, and Quality
Maximize Availability: Eliminate Equipment Failures
Forecast failures 7-14 days early with predictive maintenance. Sensor data, equipment logs, and process signals combine to eliminate unplanned downtime - the #1 killer of Availability. Turn reactive maintenance into proactive prevention.
Boost Performance: Fix Bottlenecks & Speed Losses
Constraint-aware optimization identifies hidden bottlenecks, eliminates micro-stoppages, and recovers nameplate speed. Modeling production flows improves Performance scores from 75% to 95%+. Maximize throughput without new equipment.
Improve Quality: Catch Defects at Root Cause
ML-based quality control for SEM, AOI, and inline inspection detects systematic defects invisible to traditional SPC. Eliminate startup and production defects that destroy your Quality score. Improve yields while reducing scrap and rework costs.
Real-Time OEE Dashboards & Analytics
Live visibility into Availability, Performance, and Quality losses. Automated reporting of the Six Big Losses includes drill-down to root cause. Integration with MES/ERP systems and automated root cause summaries that explain why losses happened.
Proof: Real-World Value
Quantifiable results from production deployments.
Prioritized Maintenance Platform: $2.4M Annual Value
Simulation-based maintenance ranking system that prioritizes interventions based on quantified workshop capacity impact ($2.4M/year recovered).
Integrated Operations Planning & Optimization
Mathematical programming framework for capacity optimization and constraint-based scheduling, solving complex multi-objective problems in seconds.
Automated Data Review Platform: 10% Faster Analysis
Automated analytics platform that accelerated quality data review from hours to minutes. Identified outliers in 40k+ sensor readings per batch automatically, improving analysis throughput by 10%.
Manufacturing Performance Monitoring Suite
Real-time dashboards and anomaly detection for 200+ sensors, shifting strategy from reactive failures to predictive insights.
Defect Classification Evaluation Framework
Production-aligned evaluation framework for defect classifiers using cost-weighted metrics, surpassing standard F1 scores for high-stakes manufacturing.
Calculate Your Potential Savings
Calculate what you're losing to preventable OEE losses right now
* These are estimated calculations for illustration purposes. Actual results vary based on specific operational conditions.
Is Your Operation Leaving Money on the Table?
Take our 2-minute diagnostic to find out
Start Small, Prove ROI, Then Scale
€45K pilot proves 5-point OEE improvement. Then scale to €10-20M in recovered value.
OEE Diagnostic (2-3 weeks)
Deep-dive analysis of YOUR production data. The system quantifies all Six Big Losses, breaks down OEE by line and shift, and builds a prioritized roadmap. This is where the real diagnostic happens—not a 1-hour call, but 2-3 weeks of data forensics.
Deliverables
- Six Big Losses quantified using your actual data
- OEE breakdown by line/shift (Availability/Performance/Quality)
- 5-point improvement roadmap with ROI estimates
- Actionable: Use it yourself or hire us to execute
Investment
€14K - €27K
Expected Value
Analysis identifies €2-6M in recoverable value
Pilot Project (6-12 weeks)
Fast-track OEE solution on 1-2 lines. Prove 3-5 point OEE improvement before scaling. Fixed scope, validated on your production data, deployed in 90 days.
Deliverables
- Predictive maintenance OR constraint optimization
- Validated OEE improvement (documented baseline → result)
- Real-time OEE dashboard + alerting
- Business case for scaling to more lines
Investment
€45K - €135K
Expected Value
€135K pilot → €2-4M annual value = 15-30x first year
Multi-Line Rollout (3-9 months)
Scale proven OEE solution across 5-20 production lines. Seamless MES/ERP integration, change management, and team training enable sustained 5+ point OEE improvement facility-wide.
Deliverables
- Production-grade deployment across lines
- MES/ERP integration with existing systems
- Team training: Sustain OEE gains long-term
- Executive dashboard: Track OEE by line/shift/loss
Investment
€180K - €720K
Expected Value
€720K investment → €10-20M value over 3 years
Ongoing OEE Excellence
Continuous model retraining as your processes evolve. Identification of new OEE opportunities and advisory on next-gen improvements keep you ahead of the world-class 85% benchmark.
Deliverables
- Quarterly model updates & retraining
- New OEE opportunity identification
- Strategic advisory on manufacturing tech
- Sustained competitive advantage via OEE
Investment
Custom retainer
Expected Value
Sustain world-class OEE vs. competitors at 70-75%
Most clients start with Phase 2: The €45K-€135K pilot.
Prove 3-5 point OEE improvement on 1-2 lines in 90 days. Walk away with documented ROI before you scale.
90 Days to 5-Point OEE Improvement
From diagnostic to measurable OEE gains—proven on your production data, not lab conditions
Week 1-2: Identify Your Costliest OEE Loss
Which of the Six Big Losses is bleeding productivity most? Analysis of your equipment data—not generic benchmarks—reveals the truth. Pareto analysis pinpoints where 5 points of OEE improvement will come from. You get a prioritized roadmap with ROI estimates.
Key Methods:
Week 3-8: Build & Validate OEE Solution
Deploy predictive maintenance for Availability losses. Fix Performance bottlenecks with constraint optimization. Catch Quality defects at root cause. Validated on YOUR production data under shadow mode testing. No disruption to live operations.
Key Methods:
Week 9-12: Deploy & Measure OEE Gains
Production-grade deployment with real-time OEE dashboards. Track Availability %, Performance %, Quality % daily. Teams are trained to sustain gains. Actual OEE improvement is measured against baseline—targeting 5 points within 90 days.
Key Methods:
Is This You?
We work with plant managers and operations leaders who are tired of leaving €2M+ on the table
We're a Great Fit If You:
- Your OEE is stuck at 65-75% when you know it should be 85%+
- Unplanned downtime costs you €50K+ per incident—and you're tired of reacting
- You have production data but lack the expertise to turn it into OEE gains
- Your plant/operations leadership is measured on OEE and needs results
- You have €45K-€135K budget to pilot a solution that proves ROI first
Not the Right Fit:
- Your OEE is already 85%+ (call us when you want to hit 90%)
- You want dashboards and reports, not actual productivity improvement
- You expect 5-point OEE gains without investing in analytics infrastructure
- You need staff augmentation, not a results-driven solution partner
If you're in the "Great Fit" column, let's talk.
Every week you wait is another week of lost OEE. Schedule a strategy call to start recovering that lost productivity.
Ready to Improve OEE by 5 Points?
Let's identify which of the Six Big Losses is costing you most
Download: OEE Diagnostic Framework
Get our Six Big Losses Assessment Template + expert newsletter. Learn how to quantify which OEE component is bleeding productivity most—and where to start improving.
Instant access to our Six Big Losses diagnostic template + case studies with real OEE improvement data
1-Hour OEE Strategy Call
We'll discuss your current OEE, identify your biggest loss (Availability, Performance, or Quality), and estimate potential value. Walk away knowing if we're the right partner to recover your lost productivity. Zero pressure.
Book 1-Hour Strategy CallFree consultation • Understand your OEE gap • Rough value estimate • No obligation
Or Reach Out Directly
Alexandre Moritz, Ph.D
Technical Lead & Co-Founder
Technical Lead & Co-Founder. Ph.D. in Industrial Engineering and Master in Computer Science. Specialized in semiconductor maintenance optimization and building prescriptive systems that can process 50M+ sensor readings daily.
Connect on LinkedInNo spam. No hard sells. Just data-driven analysis of your Six Big Losses and a clear path to 5-point OEE improvement.