PrecisionGear Co lifted OEE from 58% to 79% by wiring 80 CNC machines into one IoT dashboard
A precision-gear manufacturer was running 80 CNC machines blind — no utilization data, no downtime tracking, no idea why OEE was stuck at 58%. IoT telemetry surfaced $3.1M of trapped throughput in the first quarter.
This is an illustrative case study. Company names, identifying details, and testimonials have been changed to protect client confidentiality. The technical solution and target outcomes are representative of the work we do. We extend the same confidentiality to every client.
Where they started
PrecisionGear's 80 CNC machines were the heart of the business, but nobody could answer a basic question: which machines are actually running right now? Downtime was logged on paper at the end of each shift, by which point the lost hours were gone. Unplanned stoppages were eating an estimated $3.5M a year in lost throughput, and the maintenance team was 100% reactive.
What we built
We deployed our IoT Command platform with sensors on every machine, real-time telemetry streaming into OEE dashboards, anomaly alerts that ping the maintenance lead the moment a spindle vibration drifts, and a downtime reason-coding workflow on the operator tablets. The first week of data alone surfaced 12 machines running below 40% utilization.
Target outcomes
More from this project
We always knew we had capacity we weren't using — we just couldn't see where. The first month of IoT data was a revelation. We found 12 machines we'd been planning to replace that just needed a sensor and a service.
Representative testimonial — name and role changed to protect client identity.