“Currently, the most commonly tracked KPIs [key performance indicators] are downtime, output, and performance,” states Jorge Izquierdo, PMMI’s vice president, market development. “Study respondents also identified predictive maintenance metrics, AI [artificial intelligence]-driven recommendations, and root cause analysis as key areas that could be improved.”

Over the next three years, processors using OEE protocols will likely realize the greatest value from identifying operational efficiencies, preventive maintenance insights, production improvements, increased visibility, enhanced cost control and decision-making, and better planning and scheduling, according to the study. 

A smaller set of emerging and unique services stands out as less common but potentially indicative of where the manufacturing industry is headed, according to PMMI’s State of the Industry Report 2025. These include digital twin models, smart technology integration, and bundled performance improvement packages based on OEE benchmarking. 

“While not yet widespread, these offerings are frequently used by suppliers looking to differentiate themselves or to appeal to high-value customers seeking advanced capabilities,” Izquierdo explains.

Respondents in the 2025 report provided several thoughts about using AI to assist operators via human-machine interfaces (HMIs), analyze OEE in real time, or enable predictive diagnostics based on sensor data. While promising, these applications face two key hurdles: the reluctance of processors to share machine data and the added costs of implementing AI systems. Plus, many smaller or mid-sized customers view these barriers as too high.

Optimizing Lines 

While food processors using OEE can find ways to run lines with fewer people, OEE optimization is far more of a systems issue than a machine issue. 

“For example, if one machine in an integrated packaging line isn’t performing as specified, the entire packaging system may be impacted,” Izquierdo says.

Food processors that gain advantages using OEE don’t merely review numbers on reports. Instead, savvy processing leaders give operators and engineers the data that can help solve real problems, such as recurring jams, longer than usual changeover times, or quality issues that create rework.

But OEE can be a moving target for some manufacturers. For instance, from a controls perspective, code can be written in a PackML structure to make it more OEE-ready. However, machinery runtimes and the various auxiliary equipment and materials that could produce bottlenecks or line stoppages must be constantly monitored.

Currently, original equipment manufacturers (OEMs) are including high-level OEE features in their machinery, such as live monitoring/remote access, standard OEE/KPIs, predictive maintenance, automated reporting systems, remote training, parts ordering, and documentation and videos. 

Modern solutions provide data visibility through HMI screens, third-party OEE software integration, and OEE dashboards/platforms. Standard OEE solutions typically include metrics for downtime, output, performance, quality, rejects, availability, maintenance, and sustainability.

OEMs are also planning to expand visibility on equipment for inspection and testing; palletizing and load stabilization; conveying, feeding, and handling; and bagging, pouching, and wrapping, as well as coding, labeling, printing, and reading.

OEMs surveyed reported that OEE-related metrics and capabilities currently underutilized include root cause analysis, changeover tracking, operator performance insights, energy/sustainability metrics, and downtime, quality, and defect categorization.

“Digital tools make it simple to collect and display OEE data,” Izquierdo states. “Successful use of OEE is the combination of metrics with the experience and know-how to put data into action on the plant floor.”

Regardless of where your organization is on its OEE journey, PACK EXPO International 2026 is the place to be to discover cutting-edge production solutions. Featuring 2,600 exhibitors, the all-encompassing trade show, Oct. 18-21 at Chicago’s McCormick Place, paves the way for snack and bakery producers to research the latest technologies and meet experts who can provide guidance on how to accelerate projects — all in a few days on the show floor.

More than 150 free educational sessions will be available on multiple stages. During these sessions, attendees can discover groundbreaking solutions and gain practical guidance from experts who understand today’s production challenges. Topics include automation, digitalization, operational excellence, and other breakthrough ideas. The following are a few examples of sessions that pertain to advancing OEE operations:

• Data Without the Downtime: The Value of Noninvasive Sensors
• Transform What’s Possible with Digital Twins
• From Reactive to Predictive: How Agentic AI Helps Manufacturers Win the Shift
• Beyond Machine Speed: Rethinking Packaging Line Design for Higher Throughput 

Learn more about PACK EXPO International 2026 here.

Related Hitting sustainability targets is a delicate balance: PMMI