OEE Management — a full-stack web application that transforms raw production data into strategic intelligence. Designed and built by a certified engineer with hands-on experience in high-precision CNC manufacturing.
From the Author
Not only during working hours, but every weekend I dedicate my time to analysing, planning, and engineering methods that can meaningfully improve production efficiency. As an engineer with a systems-level architectural mindset, I have been developing a comprehensive, multi-layered project that goes far beyond simple equipment tracking — it reveals not only overall equipment effectiveness, but also the strengths and weaknesses of individual departments, machines, and the personnel directly involved in production processes.
My name is Oleksandr Velyvchenko. I am a highly qualified, certified, and diploma-accredited engineer and software developer with extensive experience in both leadership and industrial engineering. My specialisation lies in high-precision manufacturing — from electronic components to multi-complex, tight-tolerance turned parts produced on advanced CNC machinery.
OEE Management is an independent side project born from the convergence of my general engineering expertise and hands-on production management experience. It bridges the gap between shop floor machinery and top-floor business processes, enabling real-time visibility, seamless integration, and data-driven automation. At its core, the system measures the delta between actual and potential performance — empowering organisations to increase capacity, reduce costs, and drive continuous improvement initiatives.
Innovative solutions, advanced mathematical formulae, rigorous statistics, and clear visual representation — all combined into an intuitive interface designed for different levels of users. The combination of statistical data collection, algorithms, flowcharts, coefficients, and real production metrics delivers a complete, accurate picture of your machine shop's performance.
You can generate reports, maintain records, integrate new departments and staff members, and track real productivity and scrap figures — all in one place. To obtain a precise understanding of the full picture of your shop floor and make timely decisions to increase efficiency.
Why Was This System Developed?
In many machine shops, production data still lives on paper forms, spreadsheets, and whiteboards. Shift handovers rely on verbal communication. Performance issues are identified weeks after they occur — if they are identified at all. I set out to solve this problem by building a system that:
- Digitises paper-based reporting — eliminating manual transcription errors and delayed data entry
- Automates complex calculations — integrating advanced mathematical formulae into an automated data processing engine
- Presents information visually — through charts, diagrams, and trend analysis that make interpretation intuitive for all levels of management
- Delivers actionable intelligence — so that supervisors and managers can make timely, evidence-based decisions
Key idea: This is not merely a data entry tool — it is a serious analytical instrument and an innovative path towards the digitisation of paper-based reports and the automation of data processing in manufacturing. The convergence of complex mathematical formulae, intelligent algorithms, and intuitive visual representation delivers precise analytical and statistical figures — presented not only as numbers, but as charts and diagrams that simplify interpretation and accelerate decision-making.
Who Can Use It?
- Machine Operators — record shift events: setups, downtime categories, production output, scrap
- Team Leaders & Supervisors — monitor shift-level efficiency, identify recurring issues, compare performance
- Production & Operations Managers — analyse trends across departments, benchmark machines, plan improvement projects
- Senior Management & Directors — access a strategic overview of the entire shop floor for resource allocation and investment decisions
The system is designed for any precision engineering or manufacturing environment — from small job shops running 5 machines to large-scale production facilities with multiple departments and shift patterns.
Technology Stack
OEE Management is a modern, full-stack web application built with industry-leading technologies:
- Framework: Next.js 14 (React 18) with App Router architecture
- Language: TypeScript — ensuring type safety and maintainability across the entire codebase
- Database: PostgreSQL with Prisma ORM for robust, relational data modelling
- Data Visualisation: Recharts library — responsive, interactive charts optimised for both desktop and mobile
- UI Components: Radix UI primitives with Tailwind CSS — accessible, responsive, and beautifully styled
- Authentication: NextAuth.js — secure session management
- PDF Generation: Server-side HTML-to-PDF rendering for professional downloadable reports
- Export Formats: PDF and Excel (XLSX) export capabilities
- Hosting: Cloud-deployed with PostgreSQL database, optimised for low-latency access
The application follows a mobile-first responsive design philosophy — every screen, every chart, every input field is optimised for use on tablets and smartphones directly at the machine, as well as on desktop monitors in the office.
Features & User Interface
📋 Daily OEE Sheets (Home Page)
The home screen displays all recorded shift entries in a filterable, sortable list. Each entry represents one shift on one machine and contains:
- Date, shift type (Night / A / B), and machine assignment
- Part number, batch size, and start count
- Time slot grid (32 slots × 15 minutes = 8 hours) categorised as: Running, Setting, Waiting (Internal), Waiting (External), Tool Failure, or Breakdown
- Part details: routed vs actual setup time, routed vs actual cycle time, production time, good parts, and scrap
- Operator comments attached to individual time slots
Filters allow you to narrow the view by date range, machine, department, or shift type.
📊 Reports & Analytics
The reporting engine is the analytical heart of the system. It processes all recorded shift data and generates comprehensive visual reports.
Charts & Diagrams
- OEE by Machine — grouped bar chart comparing Availability, Performance, Quality, and overall OEE for each selected machine. Instantly reveals which machines are underperforming.
- Downtime Analysis — pie chart breaking down non-productive time into categories (Setting, Waiting Internal, Waiting External, Tool Failure, Breakdown). Shows where time is being lost.
- Good vs Bad Parts by Shift — bar chart comparing good parts and scrap across shift types (Night, A, B). Highlights quality differences between shifts.
- Production Time by Shift — bar chart showing operating time distribution across shifts. Identifies which shifts are most productive.
- OEE Trend over Time — line chart tracking Availability, Performance, Quality, and OEE day by day. Reveals trends, improvements, or deterioration over time.
- Scrap by Shift — bar chart showing total scrap per shift type. Pinpoints which shifts generate the most waste.
- Scrap Trend over Time — line chart tracking scrap volumes day by day. Essential for identifying spikes and patterns.
- Setup Analysis by Shift — grouped bar chart comparing the number of setups, routed setup time, and actual setup time per shift. Measures setup discipline and efficiency.
Efficiency Metrics (Plan vs Actual)
The system calculates four key efficiency indicators, each expressed as a percentage (0%–100%):
- Setup Efficiency = (Avg Routed Setup ÷ Avg Actual Setup) × 100 — measures how closely actual setup times match planned times. 100% means operators are meeting or beating the target.
- Cycle Time Efficiency = (Avg Routed Cycle Time ÷ Avg Actual Cycle Time) × 100 — compares planned versus actual machining speed. 100% indicates the machine is running at or above the planned rate.
- Production Efficiency = (Effective Production Time ÷ 480 min) × 100 — where Effective Production Time = 480 − (Waiting + Failures + Breakdowns) − max(0, Actual Setup − Routed Setup). Measures how much of the available shift time was genuinely productive.
- Overall Efficiency = Production Eff. × Setup Eff. × Cycle Time Eff. ÷ 10,000 — a composite score that combines all three factors into a single performance indicator.
Colour coding provides immediate visual feedback:
- 🟢 Green (≥90%) — Excellent
- 🟡 Yellow (70–89%) — Acceptable, room for improvement
- 🔴 Red (<70%) — Requires attention
Plan vs Actual Comparison Table
A detailed table listing every shift record with routed vs actual values for setup time and cycle time, plus delta calculations showing the variance. This is essential for identifying systematic deviations from planned parameters.
🏭 Machines (Configuration)
The Machines section is the configurator for your machine shop. Here you can:
- Add a new machine — when new equipment is purchased or commissioned
- Edit an existing machine — update its name, department, work centre, type, or number of axes
- Delete a machine — when equipment is sold, decommissioned, or permanently removed from service
Each machine is assigned to a department and carries metadata such as machine type and axis count.
⚙️ Config (System Settings)
The Config page provides database management tools:
- Export Backup — download your entire database as a JSON file for safekeeping
- Import from Backup — restore data from a previously exported backup file (supports chunked import for large datasets)
- Clear All Data — perform a complete hard reset, removing all machines, shifts, time slots, part details, and comments. This returns OEE Management to a fresh state, ready for data entry from scratch.
Quick Start Guide
Step 1: Configure Your Machines
Navigate to the Machines section. Add each machine in your shop with its name, department, type, and axis count. This is a one-time setup (unless you acquire new equipment).
Step 2: Record Daily Shift Data
From the home page, click "Add New OEE". Select the date, shift type, and machine. Fill in:
- Part details — part number, batch size, routed/actual setup time, cycle times, good parts, scrap
- Time slot grid — classify each 15-minute block of the shift (Running, Setting, Waiting, etc.)
- Comments — add notes to specific time slots for context (e.g., "Tool broke at 14:30")
Save the entry. The system automatically calculates OEE metrics.
Step 3: Generate Reports
Example: Monthly report for a specific machine (1 January – 31 January 2026)
- Navigate to the Reports section
- In the filters, set the date range: 01/01/2026 to 31/01/2026
- Optionally select a Department to narrow the machine list — by default, "All Departments" is selected, meaning you see every machine in the shop displayed below
- Below the department filter, click "Clear All" to deselect all machines
- Select the machine you need — for example, Deco 1
- Click "Generate Report"
The system will process all shift data for Deco 1 within January 2026 and display a comprehensive report below, including all charts, efficiency metrics, and the Plan vs Actual comparison table. Reports can be exported as PDF for management presentations or downloaded as Excel for further analysis.
Documentation
Full technical documentation is available via the links below:
- 📖 User Manual (PDF) — comprehensive guide covering all features, workflows, and best practices
- 📜 Terms and Conditions (PDF) — user agreement and legal information
- 🔒 Privacy Policy (PDF) — GDPR-compliant data handling and cookie policy
Conclusion
OEE Management is a strategic analytical instrument that transforms raw production data into actionable intelligence. Detailed comparative reports presented not only as figures but also as charts and diagrams simplify the interpretation of information from this automated shop floor data processing system.
This is a serious engineering tool for serious manufacturing professionals.
🔗 Project: oee.psytech.site
"You cannot improve what you cannot measure." — Peter Drucker
