Industrial analytics for plants measured on OEE.
Turn the data you already collect into decisions that move maintenance, planning, quality, and daily OEE.
Principles
Why teams measured on OEE work with PrismaWerk.
Four operating principles. They show up in every diagnostic, every pilot, every dashboard we ship.
- 01
TPM methodology, not just tech
We dissect Availability, Performance, and Quality the way TPM does: MTBF, MTTR, TEEP, Six Big Losses. It's the language your operations team already speaks.
- 02
Your costliest loss, first
Not every OEE loss is worth the same euro. We use your data to point at the one that's bleeding the most productivity, so improvement starts where it pays back hardest.
- 03
90-day gains, not 2-year projects
Pilots start at €45K and deliver a measured OEE improvement in 90 days. You prove ROI before scaling, without signing up for a multi-year transformation.
- 04
Results measured in OEE points
We report in Availability %, Performance %, and Quality %, not in model accuracy. A 5-point gain typically lands at €2-4M per line. That's the scoreboard.
Methodology
A 90-day path from diagnosis to measured gain.
Three phases. Each anchored to OEE data you already have on the floor.
01 / Diagnose
Weeks 1-2: find the costliest loss
Which of the Six Big Losses is hurting you the most? We work from your equipment data, not generic benchmarks. A Pareto read shows where five OEE points are actually sitting. You leave with a prioritized roadmap and ROI estimates.
- +Six Big Losses quantified
- +Availability / Performance / Quality breakdown
- +Root-cause read on real data
- +€2-4M opportunity roadmap
02 / Build
Weeks 3-8: build and validate
Predictive maintenance for Availability. Constraint optimization for Performance bottlenecks. Root-cause detection for Quality. We validate on your production data in shadow mode, so nothing touches live operations until it's proven.
- +Predictive models on real sensor data
- +Constraint-aware optimization
- +Integration with your MES/ERP
- +Proven OEE gain before scale
03 / Deploy
Weeks 9-12: deploy and measure
Production-grade deployment with real-time OEE dashboards. Availability %, Performance %, Quality %, tracked daily. Your teams are trained to sustain the gains. We measure against baseline, targeting five OEE points inside 90 days.
- +Real-time OEE dashboards
- +Automated loss alerting
- +Team enablement and knowledge transfer
- +Documented OEE gain vs baseline
Fit check
Who we're for. And who we're not.
An honest conversation up front beats a long sales cycle that ends in misalignment.
Best fit
If most of these sound like you, we should talk.
- Your OEE sits at 65-75% when you know it should be 85%+
- Unplanned downtime costs €50K+ an event, and reacting is getting old
- You have the production data, you're missing the analytics muscle to convert it
- Plant or operations leadership is measured on OEE and needs a result
- You have €45K-€135K to pilot a solution that has to prove ROI first
Not the right fit
If most of these are true, we're not your best partner.
- Your OEE is already above 85% (talk to us when 90% is the target)
- You want dashboards to look at, not productivity to move
- You expect 5-point gains without investing in the data foundation
- You need staff augmentation, not a results-driven partner
Engagement model
Start small. Prove it. Then scale.
Four phases. Each one stands on its own. Most clients start with Phase 2: the 90-day pilot.
01 / 2-3 weeks
OEE Diagnostic (2-3 weeks)
A deep read of your actual production data. We quantify the Six Big Losses, break OEE down by line and shift, and hand back a prioritized roadmap. This is the real diagnostic, not a 1-hour call, but two to three weeks of data forensics.
- +Six Big Losses quantified on your data
- +OEE by line and shift (Availability / Performance / Quality)
- +5-point improvement roadmap with ROI estimates
€14K - €27K·Typically surfaces €2-6M in recoverable value
02 / 6-12 weeks
RecommendedPilot Project (6-12 weeks)
A focused OEE solution on one or two lines. Prove a 3-5 point gain before anyone talks about scaling. Fixed scope, validated on your data, deployed in 90 days.
- +Predictive maintenance or constraint optimization
- +Validated OEE gain (documented baseline → result)
- +Real-time OEE dashboard + alerting
€45K - €135K·€135K pilot → €2-4M annual value, 15-30x in year one
03 / 3-9 months
Multi-Line Rollout (3-9 months)
Take the proven solution across 5-20 lines. MES/ERP integration, change management, and team training turn a pilot win into a sustained 5+ point OEE gain plant-wide.
- +Production-grade deployment across lines
- +MES/ERP integration with existing systems
- +Team training to sustain the gain
€180K - €720K·€720K investment → €10-20M value over three years
04 / Continuous
Ongoing OEE Excellence
Models retrained as your processes evolve. New opportunities surfaced as the data changes. Advisory on what's coming next, so your hard-won OEE stays where you put it.
- +Quarterly model updates and retraining
- +New OEE opportunities surfaced
- +Strategic advisory on manufacturing tech
Custom retainer·Hold 85%+ OEE while competitors stall at 70-75%
Next step
Bring the OEE problem you've already tried to fix.
We turn it into a focused diagnostic, a pilot, or a monitoring workflow your team can use on shift.
60 minutes. Free. No deck, no pitch.