AI Manufacturing Automation
Most plants do not have a machine problem. They have a visibility problem.
Why It Matters
A machine that is switched on is not the same as a machine that is cutting parts. Between changeovers, waiting for material, and small stops, a lot of available time disappears.
When one machine is flat out and another sits at 42%, the fix is usually to move work, not to buy. The service compares machines and shifts and flags where capacity is wasted, so you can rebalance the load and get more out of the machines that are already on the floor.
For each machine, the service compares the time it was actually running against the time it was available to run. That single comparison turns a machine that looks busy into a real number you can question, track and improve.
The time a machine is not running is not all the same. The service separates idle time, setup and changeover, and real downtime, so a general sense that machines are slow becomes a list of specific losses you can attack one by one.
The service compares machines against each other and the same machine across shifts, then flags where utilization drops well below the rest. Managers see the low performers first and can move work to idle capacity instead of buying more.
Running time against available time for each machine, so you see how much of the day is really productive.
The time a machine was available but not running, separated out so it stops hiding inside the total.
How much time goes into changeovers and setup, so you can see where quick changes would free up hours.
Real stoppages and, where recorded, why they happened, so repeat losses become easy to spot.
The same machine across day and night shifts, so gaps between teams and patterns become visible.
The machines and shifts running well below the rest, flagged so managers know where to look first.
We pull run and stop signals, production orders and shift plans from your machines and ERP.
We set what each machine was actually available to run, per shift and per day.
AI separates running time from idle, setup and downtime, with reasons where known.
Machines and shifts are compared side by side, and wasted capacity is flagged.
Managers see the real picture, rebalance work, and track whether utilization improves.
Utilization per machine
Capacity brought into view
Machines bought too soon
Work across the floor
Idle and setup losses
Use of what you own
We build ERP and software, so we work with your real machine and production data, not a demo.
We start on the floor, with how your machines and shifts actually run, then bring in the AI.
The figures are yours to question. If a signal is weak, we say so and show how to firm it up.
We pick the approach that fits your data instead of tying you to one AI model or vendor.
Managers get a view they act on, not a dashboard that no one opens after week one.
It is an AI service that measures how well each machine is actually used. It compares running time against the time each machine was available, then breaks the rest down into idle, setup and downtime so you can see where capacity is wasted.
Raw machine hours do not tell you what good looks like. The service compares running time to available time, separates setup and idle from real downtime, and compares machines and shifts, so you see true utilization instead of a single number.
It uses the machine and ERP data you already have, such as run and stop signals, production orders, shift plans and downtime reasons. We work with what your machines and systems already record.
Often yes. Many plants run new machines while older ones sit idle for part of every shift. When you can see the real utilization per machine, you can move work around and use the capacity you already own before spending on more.
Not always. Many machines already produce run and stop signals, and a lot can be reconstructed from ERP and production data. Where a signal is missing we advise the simplest way to capture it, without a full rebuild.
No. The service is model-agnostic. We choose the approach that fits your data and keep the plan yours, so you are not locked to a single model or vendor.
Related
The other services in this section, and related pages from TCB Infotech.
No commitment. A practical first look at your utilization.
