Manufacturing
The line stopped overnight. You heard at the morning meeting
We fit the sensors, put the edge box in your panel, and build what watches and calls.
Manual inspection drifts. The defects that get through are the expensive ones.
Quality managerEquipment fails between maintenance windows, and every stop cascades through the schedule.
Maintenance leadShort stops surface in the shift report, after the throughput is gone.
Shift supervisorAutomotive and medical work needs per-part records we cannot reliably produce.
Plant manager
What changes first
The stop calls someone
A machine drawing wrong wakes a named technician, escalates, and logs every attempt.
The shift report argues back
Short stops are counted at the machine, with a reason your operator taps.
Handover is signed, not remembered
The pack is assembled before the meeting, signed by a named supervisor.
Where the work leaks, and what we build
Downtime
The line stops at night
Vibration, temperature and current sensors on the machines that hurt most, and an edge box in your panel that calls out and escalates.
The plant signs the escalation ladder. The system never stops a line.
OEE
Your OEE number is a guess
Short stops and speed loss never reach the report because nothing counts them. We count them at the machine and propose the reason code.
The operator confirms or corrects the reason with a tap.
ERP
The ERP and the floor disagree
We put a layer between your ERP and the floor that flags divergence the same shift: wrong routing, unrecorded scrap, stock that is not there.
The planner reviews each divergence. Nothing posts to the ERP unattended.
Handover
Handover lives in a notebook
What broke, what was bypassed, what is still open. We assemble that pack from the machines and the work orders, before the meeting.
The outgoing supervisor signs it; the incoming one acknowledges it.
A week with the system
- Monday
- A press drive draws more current than last week. The box calls out.
- Tuesday
- Nobody answers, so it calls the next name. The work order is drafted.
- Wednesday
- The handover pack is on screen before the meeting, and signed.
- Thursday
- A short stop repeats on one station. The operator taps the reason.
- Friday
- The week's report writes itself: downtime by line, by cause, by shift.
Illustrative example. Nothing here is a measured result.
What we would watch with you
| What we watch | How it is measured | Baseline |
|---|---|---|
| Unplanned downtime hours per line per month | Machine-state capture at the edge, not recollection. | Estimated from paper today. Phase one establishes it. |
| Mean time to acknowledge a critical stop | Timestamps from stop to a named human accepting. | Currently unmeasured. The fastest-moving early figure. |
| OEE, and specifically its performance component | Computed from captured machine events. | The definition is the fight. Agree it in writing. |
| Alert precision: the share of raised anomalies a human confirmed as real | Every accept, defer and false-alarm decision, logged. | The figure that decides whether the system survives. |
| Handover completeness | Share of shifts closing with an acknowledged record. | Unmeasurable on paper: no named recipient, no timestamp. |
The cameras and sensors watch machines and processes, never individual performance.
Questions plants ask
Do we have to replace our ERP or buy an MES?
No. Your ERP stays the system of record. We add the machine-speed layer it was never built for, and feed corrections back for your planner to approve.
Our machines are old and half of them have no digital output. Is that a problem?
No. It is the normal case. Sensors mount externally on housings and cables, without touching your control logic or your warranty. We start with the assets that cost you downtime.
How accurate is defect detection on our parts?
It depends on your defects, your lighting and your line speed. Anyone quoting a universal figure is guessing. We measure on your parts during a pilot and report the real figure.
Manufacturing
Start with one line.
Bring your downtime log, your defect photos and a maintenance history. We will tell you honestly what your data supports.
Book a discovery call