How to Reduce Downtime and Increase Machine Efficiency?

In every manufacturing company, the moment comes when you have to face the truth: the line isn’t running as it should. Production stops, employees are waiting, and you’re not entirely sure whether the issue lies with the machine, the process, or simply a lack of information.
This is where OEE – Overall Equipment Effectiveness – provides the answers. OEE is the key metric for measuring the overall efficiency of machines and equipment. But it’s not just another “paper KPI.” When implemented properly, OEE becomes a powerful tool for real production management. And that’s exactly how we approach it at Hitmark.
Read more

What Does OEE Really Measure?

OEE (Overall Equipment Effectiveness) is a tool used in the TPM (Total Productive Maintenance) philosophy that shows how much of the available time a machine is actually producing at the expected level. It combines three key components:

  • Availability – how much time was the machine physically available for operation?
  • Performance – was it running at the right speed?
  • Quality – what percentage of products were defect-free?

In theory, 100% OEE is the ideal. In practice, an OEE of 85–90% is considered world-class performance – and that’s exactly the level we help our clients achieve.

CHECK OUR OEE CALCULATOR

3x5 – The Approach Behind Our OEE Support

OEE is a measure of how efficiently resources (such as time, labor, materials, capital) are used to produce goods or services.

It is most often defined as the ratio of achieved output to resources consumed:

Productivity can be analyzed on different levels:

  • Individual – performance of a single employee
  • Organizational – efficiency of a company or facility
  • Macroeconomic – productivity of an entire economy

In the context of manufacturing and industry, we usually talk about labor productivity, machine productivity, or total productivity, which covers all resources.

Everything we do is based on our 3x5 philosophy. This is not just a slogan – it’s a set of concrete actions:

5 Years of Warranty

  • because Reliability Is the Foundation of Availability

By choosing to work with Hitmark Robotics, you get not only state-of-the-art automation solutions but also exceptional support in the form of a 5-year warranty on every integrated robotic workstation.

That’s twice the market standard. Which means:

  • Confidence in the reliability and durability of our solutions
  • Minimized risk of unplanned downtime
  • Long-term investment security
  • Dedicated service support and spare part availability

Our systems are designed for years of trouble-free operation. The 5-year warranty is proof of our commitment to quality and your success.

5 Years of Service

– we operate not only fast, but also predictably

Always Close – Support

  • Help Desk 24/7/365
  • Remote access via VPN
  • Inspection cameras at the station during the first months after launch
  • Remote or on-site specialist support when needed
  • Regular inspections under the service agreement

Operational Readiness

  • Spare parts provided at installation
  • Stock of critical components in Hitmark’s warehouse
  • Express production and delivery of custom elements directly to the customer
  • Guaranteed station recovery time – max. 72 hours (on business days)

The effect? Real improvement of OEE and full control over the process.

5 Quality Standards

– because Quality Is Not a Slogan, It’s a Complete System

Our solutions are built on five quality standards, forming the foundation of every project:

  • Robotics – selecting and integrating industrial robots tailored to process requirements
  • Automation – full process control with advanced control systems
  • Design & Mechanics – precise construction ensuring reliability and ergonomics
  • Electrical Systems – compliance with the highest safety and energy standards
  • Software & Analytics – monitoring, reporting, and process optimization tools
01

Robotics

Precision That Delivers Real Results

Why it matters:

  • FANUC Roboguide simulations guarantee optimal robot trajectories and reach before installation.
  • Simulations confirm maximum axis lifespan with the tested product and gripper.
  • In-house gripper tests – with real customer products – eliminate errors and optimize gripping.
  • Predefined motion sequences shorten deployment time and simplify future modifications.

Impact on OEE:

  • Availability – fewer downtimes thanks to proven motion paths
  • Performance – optimized trajectories = faster cycles
  • Quality – fewer errors in pick-and-place operations
02

Automation

A System That Thinks, Controls, and Keeps Production Running

Why it matters:

  • HMI parameterization – quick correction of all machine parameters
  • Modular function blocks enable rapid implementation of new features
  • Automatic line changeover – no operator intervention or stoppage when switching products

Impact on OEE:

  • Availability – shorter changeovers and quick recovery after errors
  • Performance – elimination of manual operations during product changes
  • Quality – automatic parameter control reduces errors
03

Design & Mechanics

Engineered for Performance and Reliability

Why it matters:

  • Ergonomic workstations – fewer errors and faster operator tasks
  • 3D layout validation and load simulations – eliminate issues before production
  • Final 3D design delivered with full part descriptions – easy identification of station elements
  • Optimized construction – better service access and improved safety

Impact on OEE:

  • Availability – shorter service times, fewer breakdowns
  • Performance – optimized product flow and operator tasks
  • Quality – higher repeatability of all operations
04

Electrical Systems

Built to Eliminate Downtime

Why it matters:

  • Every wire labeled = instant diagnostics
  • EPLAN documentation + standardized components = immediate access to parts and schematics
  • In-house cabinet building – full quality control at every stage

Impact on OEE:

  • Availability – faster service and repairs
  • Performance – quicker deployments and testing
  • Quality – compliance with standards, zero technical errors
05

Software & Analytics

Technology That Measures, Analyzes, and Suggests Improvements

Why it matters:

  • Full documentation of the station accessible directly from the system – always up to date
  • Advanced logs and error statistics – enable fast diagnosis and elimination of downtime causes
  • Production statistics – cycles, downtimes, performance – all in real time
  • OEE indicators visible on the panel or system – complete control
  • Predictive maintenance – the system suggests when to act before failures occur
  • Identification of process bottlenecks – data drives real process optimization

Impact on OEE:

  • Availability – predictive maintenance minimizes failures and unplanned downtimes
  • Performance – bottlenecks identified and eliminated with hardware or software fixes
  • Quality – better data = fewer errors, less waste, tighter control

Thanks to these foundations, we can guarantee machine availability levels of up to 97% – proven not only in theory but in real manufacturing plants, both in Poland and abroad.

Machine Efficiency Starts With Data

You can’t manage what you can’t see. That’s why we support our clients not only in OEE integration but also in:

  • Live data collection from machines
  • Analysis of micro-downtimes and hidden delays
  • Failure prediction based on online measurements
  • Building reporting systems that are understandable not only to engineers

Remote support (VPN), 24/7 service, and fast access to spare parts are not extras – they are essential elements that keep production stable and available.

OEE Is Not the Goal. It’s the Starting Point of Smart Optimization

We know your goal is not simply “to improve OEE.” Your goals are to:

  • Produce faster and at lower cost
  • Reduce downtime
  • Increase machine utilization
  • Relieve people from manual reporting
  • Have process control without being stuck at the line

And this is exactly where OEE measurement can help you. Even better – our upcoming OEE calculator will allow you to estimate the real efficiency of your line by yourself.

Why Work With Us?

Because we don’t see OEE as just numbers. For us, it’s a tool that, when properly integrated into the process, allows you to:

  • Detect problems before they become costly
  • Understand where you’re truly losing time
  • Translate every minute of downtime into real money
  • Regain control over your production

You don’t need a full MES system, nor invest tens of thousands of euros. Sometimes it’s enough to start with one machine, one process, one shift.

And with a conversation.

OEE CALCULATOR

OEE Calculations

Availability = - %
Performance = - %
Quality = - %
OEE = - %

Calculate How Much You’re Really Losing (or Gaining) in Production

Our OEE Calculator is a practical tool for production managers, engineers, and plant owners who want to quickly and clearly assess machine efficiency.
Just enter a few key data points – available time, number of produced units, number of defects – and the calculator automatically shows not only the OEE value but also its components: availability, performance, and quality.

Why it’s worth it:

  • Get a clear efficiency snapshot – in a minute, not weeks of analysis
  • See where your resources are being lost – speed, quality, or unplanned downtimes
  • It’s the first step to real optimization – not a “paper KPI,” but data you can convert into money

Not Sure Where to Start?

The OEE Calculator is the perfect tool to see your process in numbers – and to understand how much every minute of downtime truly costs.

No installation, no MES systems – just one machine and one afternoon.

Try it yourself – launch the calculator and see how much more efficient your line can become.

FAQ

OEE (Overall Equipment Effectiveness) is a metric that shows how much of planned production time is actually spent on valuable output. It’s a key KPI that helps identify micro-downtimes, performance issues, and quality losses – and then translate them into real costs.
You need three basic inputs: availability (how much time the machine actually ran), performance (whether it produced at the expected speed), and quality (the percentage of products meeting the standard). The OEE calculator allows you to quickly input these values and get a clear result.
No. Our tool works independently of MES or SCADA systems. You only need data from one shift or one machine – perfect if you want to start analysis without expensive implementations or long integration projects.
The OEE result is not the end – it’s the beginning of smart optimization. High OEE means your equipment is running well. Low OEE means it’s time to look into the root causes of losses. With the OEE calculator, you can see if the issue is downtime, breakdowns, or lack of process standardization. It’s the first step to savings and higher productivity.
Contact Form

    I consent to the processing of my personal data for the purpose of contacting me in connection with an enquiry or request sent via the contact form. Consent to data processing is voluntary, but necessary to receive a response. Consent may be withdrawn at any time without affecting the lawfulness of processing prior to its withdrawal. The administrator of personal data is Hitmark Sp. z o.o., ul.Platynowa 3 05-090 Wypędy, NIP: 123 10 57 785

    chevron-upchevron-down