Real-time assessment of the overall effectiveness of legacy machine tools

In the last decade, metalworking firms around the world faced the challenge of embracing Industry 4.0. Amidst this, some machining companies battle with outdated, unconnected equipment on their shop floors. This work introduces a novel methodology linking machining events to electrical power behavior, enabling real-time monitoring of machine tool states. The prototype, OEE-Plus, tested on a legacy transfer line, extends Overall Equipment Effectiveness by incorporating an energy consumption indicator. The significant result is a practical solution empowering small to medium-sized enterprises to assess the efficiency and sustainability of their legacy machinery.