Unlocking Hidden Capacity with OEE & Condition-Based Maintenance

29.09.2025

Every plant leader asks the same question:  
How do we get more from the assets we already have?

The answer often isn’t buying new equipment. It’s finding 
and fixing the hidden inefficiencies that quietly drain performance.
Two of the most effective ways to do that are:

1.Optimizing OEE (Overall Equipment Effectiveness)

2.Implementing best practices in condition-based maintenance

Together, they unlock capacity you didn’t know you had - 
while boosting reliability, efficiency, and profits.

OEE Optimization: The Secret to
Hidden Capacity

OEE (Overall Equipment Effectiveness) measures how well your equipment 
is actually performing versus its full potential. It looks at:

With true integration, predictive maintenance becomes a profit driver:

Availability →  Is the machine running when it should?

Performance →  Is it running at full speed?

Quality → Is it producing good parts without rework?

Even small inefficiencies in these areas add up. A 5% drop in availability, 
5% in performance, and 5% in quality equals nearly 15% lost capacity.

By optimizing OEE, plants can:

Increase asset performance without major capital spending

Improve production efficiency and throughput

Make smarter decisions on where to focus maintenance and improvement efforts

This is exactly why we created OEEMatrix™ - a tool designed to give you real-
time visibility into OEE and show where your hidden capacity lives.

5 Best Practices for Condition-
Based Maintenance

While OEE tells you what’s happening, condition-based maintenance tells you
what to do about it. Instead of maintaining equipment on a calendar, CBM
uses real-time data to service machines only when they actually need it.

Here are 5 best practices every plant should follow:

Start with high-value assets → Focus CBM on the machines that cost the most to fail.

Use multiple monitoring methods → Combine vibration, temperature, and ultrasound data for a complete view of asset reliability.

Integrate with your CMMS → Ensure insights trigger work orders, not just alerts.

Train your team →  Make sure technicians understand how to act on condition-based insights.

Measure and improve → Track the impact on downtime, repair costs, and OEE to prove value and keep improving.

Plants that embrace CBM consistently report better asset reliability and
reduced downtime - while saving money on unnecessary maintenance.

Why Industrial Matrix?

Most providers stop at dashboards. Industrial Matrix connects the dots 
by integrating OEE monitoring with condition-based maintenance insights
in one predictive reliability suite.

OEEMatrix™ to pinpoint hidden capacity losses in real time

Wireless sensors to feed vibration, temperature, and ultrasound data

AI-powered analytics to highlight true priorities

Seamless integration with CMMS, ERP, and EAM platforms

The result: not just data, but a playbook for efficiency - 
actionable, measurable, and tied directly to ROI.

Real-World Results

By combining OEE optimization with condition-based 
maintenance, companies have achieved:

10–15% increase in available capacity without new machines

30–40% reduction in unplanned downtime

Stronger asset performance across production lines

That’s efficiency you can measure - and money you can take to the bank.

Take Action Today

Your hidden capacity is waiting. The question is: 
will you find it before your competitors do?

of OEEMatrix™ and see your OEE in real time

Book a Demo

today to start building your efficiency playbook

Chat with an expert

🔥 Don’t let wasted capacity slow you down. Optimize OEE. 
Embrace condition-based maintenance. Win with Industrial Matrix.

Unlocking Hidden Capacity with OEE & Condition-Based Maintenance

OEE Optimization: The Secret to
Hidden Capacity

5 Best Practices for Condition-
Based Maintenance

Why Industrial Matrix?

Real-World Results

Take Action Today

Other blog articles

Predictive Maintenance Across Food & Automotive Manufacturing

Connecting Predictive Maintenance to Your Entire Plant