PGT Industries OEE Implementation with ICONICS Productivity Analytics

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PGT Industries OEE Implementation with ICONICS Productivity Analytics

Case study showing how PGT Industries used ICONICS Productivity Analytics to analyze OEE across 12 assets, identify losses, and increase output without plant expansion.

Published

June 4, 2026

Read time

3 min read

Source

PGT Industries deployed ICONICS Productivity Analytics and GENESIS32 to measure OEE on critical glass manufacturing lines. The system integrated data from Allen-Bradley, Beckhoff, and other controllers to expose availability, performance, and quality losses. Real-time dashboards and drill-down analysis enabled rapid corrective actions that raised capacity enough to cancel a planned expansion and reduce operating days from seven to five.

Key takeaways

OEE visibility across 12 assets revealed hidden downtime and performance gaps previously attributed to equipment limits

Integration with existing PLCs and SQL databases enabled unified analysis without replacing control systems

Cross-functional teams used real-time alerts to correct issues such as excessive startup meetings and material handling delays

Production output rose sufficiently to cancel capital expansion and cut labor and energy costs by approximately 20 percent

OEE metrics became standard in daily operations reviews, driving sustained cultural focus on capacity utilization

Market overview

SCR methodology note

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