Tap into your hidden capacity with proven productivity step changes in less than 3 months. Unlock those ‘hidden’ assets within your plant or across your plant network by engaging and retaining your frontline teams.
With Redzone, you’ll see miraculous results — including measurable OEE improvement — in the first 90 days; but the improvements don’t stop there! As you continue to use Redzone and add on additional capabilities, you’ll see continued results that keep adding to your overall productivity, engagement, and retention metrics. Overall, your frontline teams will be achieving world-class outcomes!
See how organizations like yours harness the power of Redzone’s Connected Worker Technology to maximize business outcomes.
Want to see how much OEE improvement could boost your bottom line? Use our OEE calculator to estimate potential savings based on your plant’s current performance. Just input a few basic metrics—like volume, labor rate, and OEE—and discover how much additional throughput and labor cost savings you could unlock in just 90 days with Redzone.
Wondering what’s possible for your specific factory? Scroll down to explore our real-world results and benchmark data from over 1,500 plants of every size and in every industry using Redzone.
Find out how much Redzone could save your plant by using our savings calculator below.
For example in million lbs or units
including maintenance and material handling
estimate
including benefits
Average 47.4%
average 12%
Reduction in Labor Costs
Additional Throughput
per year
Million Lbs (units) per year
Overall Equipment Effectiveness (OEE) is the gold standard for measuring manufacturing productivity. It combines three key components – Availability, Performance, and Quality – that together provide a comprehensive picture of how effectively a plant is operating.
The formula is:
OEE % = Availability % × Performance % × Quality %
Each factor reveals a different type of loss — whether due to downtime (Availability), slower cycles (Performance), or product defects (Quality). OEE helps manufacturers pinpoint areas for OEE improvement.
OEE is a reflection of available opportunity. OEE calculates what percentage of all opportunities available in a perfect world were translated into good, sellable product.
Achieving sustained OEE improvement starts with addressing hidden sources of loss – what is reducing those opportunities – across your operations. These losses typically fall under three core components of OEE: Availability, Performance, and Quality.
Availability losses come from both unplanned stops, like equipment breakdowns, and planned downtime, such as changeovers or cleanings. Performance losses are caused by slow cycles and minor stops that prevent operations from running at optimal speed. Quality losses reflect defects and rework—products that don’t meet standards the first time.
Left unaddressed, these losses chip away at productivity and profitability. Want to know how Redzone works to reduce these losses across your plant? It starts by empowering your frontline teams with real-time visibility, collaborative tools, and data-driven decision-making—so they can take immediate action where it matters most.
Redzone is known for delivering rapid OEE improvement—most customers experience measurable gains within just 90 days. In fact, our productivity benchmark report focuses on the OEE increases seen during the first 90 days of using Redzone. Our ROI projections are based on real production metrics like initial OEE, labor costs, and expected uplift. With our simple plug-and-play approach, you’ll be tracking gains in throughput and efficiency in weeks, not months.
OEE improvement isn’t just about running equipment faster—it’s about doing more with what you already have. Increasing OEE means increasing efficiency – allowing you to run more product – with less waste – every shift. That translates into more capacity – with the exact same equipment you’re running today. You can delay – or even eliminate – large capital expenditures for new machines, adding shifts or headcount, or increasing your factory footprint.
Even a modest improvement in OEE—from 60% to 68%, for example— unlocks significant gains in throughput and reduces labor spend and material waste. These improvements translate directly to increased profitability – in just 90 days – without requiring major operational changes or budget reallocations.
Use our OEE calculator above to simulate how small changes in your current performance could delay your next capital investment and maximize existing capacity.
Real metrics from real manufacturers: Data from over 1,500 plants, reporting back to us on millions of production runs, demonstrate consistent OEE improvement, productivity increases, and stronger engagement after only 90 days with Redzone.
Five days’ production in four days. Proven in over 1,500 factories worldwide, OEE improvement and productivity step changes are a predictable and transformational outcome achievable in just 90 days.
Based on actual anonymized production data directly from the plant and equipment, the productivity benchmark report offers unmatched insight into OEE improvement and plant efficiency — making it the most comprehensive study of its kind. The study includes:
A spring in the step, a smile on the face and rowing together: an engaged frontline workforce is the the difference between winning and losing. Win the battle for engagement and watch your staff turnover decline overnight.
Based on on-site assessments, our Engagement Study explores how 150 plants authentically transformed their levels of frontline engagement by tapping into the laws of human nature.
These plants increased productivity and reduced staff turnover by focusing on these five areas of engagement:
OEE (Overall Equipment Effectiveness) is a standard industry method of calculating productivity
It’s calculated but multiplying three core metrics: Availability, Performance, and Quality.
Availability % – percentage of the scheduled line time that the line is actively running product
Performance % – actual run rate as a percentage of theoretical maximum run rate
Quality % – first-pass quality, or percentage of total parts produced without defect
OEE is calculated as:
Availability % x Performance % x Quality % = OEE
e.g.: 95% x 95% x 95% = 85.7% OEE
Redzone empowers frontline teams with real-time visibility, collaboration tools, and digital workflows to reduce downtime, speed up problem-solving, and increase first-pass quality. This connected approach enables fast, continuous OEE improvement across every line, shift, and plant. Knowledge capture, best-practices sharing, and problem resolution history ensure that improvements made are sustainable.
Use our OEE calculator to estimate how much performance improvement and cost savings your facility could gain over time. Just enter your current throughput, labor costs, and baseline OEE to see projected output increases and labor reductions within 90 days.
No, you don’t need to know your current OEE before starting Redzone. The majority of factories do not collect the data required for accurate OEE calculations. It’s not until Redzone is turned on that factories get full transparency on what their OEE is – and the full set of opportunities still available every day.
Redzone’s 2025 Benchmark Report studied the starting OEE of each of the 1500 factories that deployed the 90-day program. The average baseline OEE – the OEE on day 1 of the 90-day program – was only 47%. The Benchmark Report breaks out baseline OEE by factory size, industry, and region and you can use it to see the average starting OEE of factories like yours.
It’s interesting to note that most plants that had OEE monitoring systems in place prior to Redzone found that they had been overreporting OEE by nearly10pts on average. Many OEE systems fail to capture defects (first past quality losses) on OEE. Additionally, simplistic OEE systems lack contextual granularity, such as differences in OEM rate by product format and standards for Changeovers.
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