Real-time machine utilization tracking and automated OEE analytics with non-invasive sensor retrofitting.
The Problem
Most plants do not know how long each machine really runs. Supervisors walk the floor, operators report from memory at shift end, and idle time hides inside “production” hours. Owners see output at the end of the day but cannot see why it fell short.
The Sensor
A clamp-on current sensor (CT) or a signal tap from the machine's tower light detects whether the machine is running, idle or stopped. It installs without opening the control panel, works on old and new machines, and needs no PLC or machine manufacturer support. A small node sends the status to the Poldu Edge Gateway every few seconds.
The Dashboard Result
- A live floor view with each machine shown as running, idle or stopped
- Utilization percentage per machine, shift and day
- OEE broken into availability, performance and quality
- A timeline of every stop, with duration
- Alerts when a machine has been idle longer than a set limit
How It Improves Performance
- Higher utilization: you see hidden idle time and recover it.
- Faster response: supervisors are alerted the moment a machine stops, not at shift end.
- Fair comparison: shifts, operators and machines are compared on the same facts.
- Better planning: real run-time data replaces guesses in production plans.
Best For
Fasteners, forging, CNC and machining, plastics, textiles, packaging, foundries and any plant with motors or powered machines.
Call to Action
Put your first 3 machines online with the Poldu Starter Kit.