Case Study: Avalign Technologies boosts OEE and throughput with MachineMetrics

Optimizing Overall Equipment Efficiency and Utilization

Avalign Technologies, a medical device OEM serving the healthcare industry, needed better visibility into machine utilization across its U.S. plants. Before working with MachineMetrics, operators tracked production manually with spreadsheets and paper logs, making the data unreliable and slowing efforts to reduce downtime, improve throughput, and understand bottlenecks in lathe and grinding operations.

MachineMetrics was implemented on Avalign’s lathe and grinding machines, using real-time machine data, dashboards, alerts, and Digital IO for legacy equipment. The results were significant: OEE rose from 25–30% to above 60% and even 80% weekly, throughput increased 9.9%, idle time dropped from 980 hours to 2 hours, 14,000 hours were saved on grinders, and Avalign generated more than $4.5 million in increased throughput over nine months.

Avalign Technologies

Matt Townsend

OEE Director