Resources for people who have to decide something this week.
Definitions that match the standards, methods explained without jargon, and free calculators that do the arithmetic. No sign-up, nothing stored.
OEE to ISO 22400-2Free calculatorsNo sign-up, nothing storedISO 10816 vibration zones
| Section | Pieces | Start with |
|---|---|---|
| OEE | 15 | What Is OEE? |
| Connectivity | 6 | Connect a CNC |
| Protocols | 4 | MTConnect vs OPC UA |
| Vibration | 4 | Defect frequencies |
| Cost & energy | 4 | What downtime costs |
| Signals & mapping | 3 | PLC Signal Mapping |
Calculators run in your browser: no sign-up, nothing stored.
Illustrative9 SECTIONS
Reference material for people who have to make a decision about a machine this week: how the standard definitions actually work, what a measurement means once you have it, and free tools that do the arithmetic without asking for an email address.
Everything here is written by the team that runs the platform. Where a figure comes from an external standard or a published industry benchmark, we say so and name the source.
OEE, defined and calculated
The metric, the standard behind it, and the arithmetic worked with Indian shop-floor numbers. Every formula states ISO 22400-2 first and discloses our variant alongside.
OEE, DEFINED AND CALCULATEDWhat Is OEE?The three factors, what each measures, and who owns it.OEE, DEFINED AND CALCULATEDHow to Calculate OEEOne shift worked end to end, both definitions, loss in rupees.OEE, DEFINED AND CALCULATEDAvailability, Performance and QualityThree separate diagnostics, and how to read them together.OEE, DEFINED AND CALCULATEDIdeal Cycle Time ExplainedThe input that decides whether performance means anything.OEE, DEFINED AND CALCULATEDISO 22400-2 Definitions ReferenceThe standard definitions, and our variant disclosed alongside.OEE, DEFINED AND CALCULATEDOEE and Industry 4.0What automation changed, and why your number will fall.OEE, DEFINED AND CALCULATEDOEE for CNC MachinesWhat the control gives you, and the four assumptions that corrupt it.OEE, DEFINED AND CALCULATEDWhat Is a Good OEE?Four tests that work regardless of what your number is.OEE, DEFINED AND CALCULATEDWorld-Class OEE: 85% of What?Where the figure comes from and what it assumes.OEE, DEFINED AND CALCULATEDThe Six Big LossesThe loss tree, and the three losses plants under-record.OEE, DEFINED AND CALCULATEDManual vs Automated OEEWhere the blind spot is, and why the number falls.OEE, DEFINED AND CALCULATEDOEE vs Machine UtilizationBusy is not the same as productive.OEE, DEFINED AND CALCULATEDOEE vs TEEPSame losses, different denominator.OEE, DEFINED AND CALCULATEDOEE vs ProductivitySymptom and diagnosis, and when they disagree.OEE, DEFINED AND CALCULATEDFree OEE Excel TemplateBoth definitions in a spreadsheet, losses in rupees, no email required.
Getting a machine connected
How machine data actually reaches a monitoring system, and the decisions that determine whether it is trustworthy.
GETTING A MACHINE CONNECTEDHow to Connect a CNC to an OEE SystemThe six steps in the order they happen, and the mistakes that cost time.GETTING A MACHINE CONNECTEDHow CNC Machine Data Is CollectedOne data point followed from spindle to screen, in plain terms.GETTING A MACHINE CONNECTEDCNC Machine Data AcquisitionSampling, timestamps, buffering and telling measured from inferred.GETTING A MACHINE CONNECTEDCNC Machine Connectivity MethodsFive methods compared, and a per-machine decision order.GETTING A MACHINE CONNECTEDMonitoring Without InternetWhat works offline, and the three arrangements plants use.GETTING A MACHINE CONNECTEDCNC IP Address AssignmentWhere FANUC, Siemens, Mitsubishi, Haas and Mazak keep network settings.
Protocols and standards
OPC UA, MTConnect and Modbus explained on the criteria that decide which one applies to a given machine.
PROTOCOLS AND STANDARDSOPC UA for Machine MonitoringWhat the standard gives you, and where specifying it narrows your options.PROTOCOLS AND STANDARDSMTConnect for CNC MonitoringA read-only standard built for machine tools.PROTOCOLS AND STANDARDSMTConnect vs OPC UADirect comparison, and why most plants need both.PROTOCOLS AND STANDARDSModbus Machine MonitoringRegister mapping, the four classic mistakes, and where it fits.
Signals, mapping and cycles
The engineering underneath: panel wiring, PLC tag mapping, and how a cycle is detected when nothing clean is available.
SIGNALS, MAPPING AND CYCLESDigital I/O Machine MonitoringPanel signals, debounce, and the electrical realities that decide longevity.SIGNALS, MAPPING AND CYCLESPLC Signal MappingThe six fields every mapping needs, and the errors nobody catches.SIGNALS, MAPPING AND CYCLESAutomatic Cycle DetectionThe detection ladder, and four ways naive detection gets it wrong.
Security
The questions an IT or customer audit will ask, and what a defensible answer looks like.
Definitions and standards
The vocabulary that causes the most avoidable arguments in Indian plants.
STANDARDOEE, defined to ISO 22400-2Availability, Effectiveness and Quality as the standard defines them — and how the MachineWise variant differs.CALCULATOROEE calculated two waysThe ISO formulation side by side with the time-in-cut variant, each loss priced separately.METHODCondition-based monitoringWhat CBM actually requires: baselines per machine rather than handbook thresholds.METHODBooked, worked and free hoursWhy utilisation and OEE answer different questions and should never be quoted interchangeably.
Vibration and machine condition
Turning a number on a meter into a decision about a machine.
CALCULATORBearing defect frequencies and ISO severityBPFO, BPFI, BSF and FTF from a designation and shaft speed, plus ISO 10816 / 20816 zones.METHODReading a spectrumDefect frequencies, sidebands and why envelope analysis finds faults a velocity reading misses.METHODBearing remaining lifeHow runtime, load history and signature combine into a usable estimate.METHODVibration monitoring in practiceSensor placement, baselines and what separates trend from threshold.
Cost, energy and the business case
Putting a rupee figure on things most plants describe qualitatively.
CALCULATORWhat downtime costsMachines, hours and machine-hour rate to a monthly and annual figure.CALCULATORWhat an OEE gain is worthRecovered capacity plus tooling savings at your own rates.METHODEnergy per good partMetering routes, idle-energy ratio and demand peaks.INDEXAll free calculatorsThe five tools in one place — no sign-up, nothing stored.
Deployment and data
Practical questions that decide whether a monitoring project survives its first month.
REFERENCEController and PLC compatibilityWhat is read natively from FANUC, Siemens, Mitsubishi, Haas and Allen-Bradley.PLATFORMOn-premises deploymentWhere production data lives, and what that means for cost and privacy.METHODCapturing stoppage reasonsFour ways to log a reason at the machine, and why interlocking changes coverage.BLOGField notesLonger articles from deployments across 150+ plants.
Ready when you are
Stuck on a definition or a number?
Send us the figure your team is arguing about. An engineer will tell you which definition it used and what it would read on a live dashboard.
Questions
Straight answers.
Are the calculators really free, with no email required?
Yes. All four run entirely in your browser, nothing you type is transmitted, and the result appears before any form is offered.
Which OEE definition should I quote to a customer?
The ISO 22400-2 definition, always, and say so explicitly. The MachineWise time-in-cut variant is useful internally because it needs no ideal cycle time, but it is not comparable to ISO-based benchmarks and should never be presented as one.
Is the bearing calculator accurate for my specific bearing?
It is accurate for the geometry you give it. Nominal geometry differs between manufacturers for the same designation, which is why every value is editable and why the page tells you to verify against your bearing's datasheet for anything critical.
Do you publish the ISO standards themselves?
No. We compute against the evaluation zones and explain what they mean; the standards are published by ISO and should be purchased for compliance work.
How often is this material updated?
Reference pages are updated when the underlying standard or our platform behaviour changes. Field notes are added as deployments produce something worth writing up.
Can I use these pages in internal training?
Yes, freely. If you reproduce a calculator's output in a report, state which OEE definition it used — that single line prevents most downstream confusion.
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