AI Shop Floor Monitoring
AI that gives you a live view of every machine. It tracks status, output, downtime and bottlenecks in real time, alerts the right person the moment a line stops or slows
Why It Matters
When a line goes down, every minute is output you do not get back. Monitoring shows the stop the second it starts and sends it to the person on that line, so the response is minutes, not the next morning.
It is not enough to know a machine was down for forty minutes. Monitoring captures why: a changeover, a material wait, a jam, a breakdown. The reasons build up, so you can see which cause is eating the most time and fix the pattern, not just the incident.
Every machine shows as running, idle or down, with its output next to the name. The same board runs on a wall screen, an office monitor and a phone, so the floor is visible to everyone who needs it at the same moment.
The moment a machine stops, or drops below the pace it should be holding, it is flagged. A slowdown that a shift report would bury shows up on the board while there is still time to act on it.
Each stop goes to the person who can act, with escalation if it drags on, on the channel they already use. The reason is logged against the stop, so over days and weeks the causes that cost you the most become obvious.
Running, idle or down for every machine, updated live, so the state of the whole floor is on one board.
Units per hour against the pace the line should be holding, so a slowdown is visible before it becomes a shortfall.
Every stop, how long it lasted, and whether it was planned, so lost time is counted instead of guessed.
Where work is piling up and which machine is holding back the line, so you fix the constraint, not a symptom.
The cause logged against each stop: changeover, material wait, jam or breakdown, building a record over time.
Repeated slowdowns and stops on a machine flagged early, so maintenance is called before it fails outright.
We read the signals your machines and sensors already send, and pull work orders from your ERP.
Status, output, downtime and pace are tracked live for every machine and line.
The moment a line stops or slows below its normal pace, it is flagged as it happens.
The right person is notified on the channel they use, with escalation if the stop drags on.
The reason is captured against the stop, so the pattern is clear over days and weeks.
View of every machine
Response to a stopped line
Downtime that goes unnoticed
Output across the shift
Reasons behind every stop
Surprises at end of shift
We build ERP and software, so machine data lines up with your work orders and production plan, not a separate silo.
We read the signals your machines and sensors already send, and add a sensor only where a signal is missing.
Boards a supervisor can read at a glance and alerts on the channels they already use, not another login to ignore.
We use the approach that fits the signal, from simple rules to machine learning, and are not tied to one vendor.
We stand up one line or cell first, show it working, then roll out across the floor.
It is a live view of your production floor. It reads machine and sensor data alongside your ERP records, shows the status of every machine, and tracks output, downtime and bottlenecks in real time. When a line stops or slows, it alerts the right person and logs the reason.
Usually not. Most machines already send status and counter signals, and many plants already have sensors and PLCs. We connect to what you have first. Where a signal is missing, we add a low-cost sensor for that one point rather than replacing equipment.
Reports tell you about a stop after the shift is over. Monitoring tells you while it is still happening, so a supervisor can act now. It also logs the reason for every stop, so the end-of-shift numbers explain themselves.
You decide. A stop on one line can go to the line supervisor, a longer stop can escalate to the plant manager, and a maintenance trigger can go to the maintenance team. Alerts go to the person who can act, on the channel they already use.
Yes. The monitoring reads machine and sensor data and reconciles it with your ERP work orders and production plan, so output and downtime line up with the jobs they belong to. It is built to sit on top of the systems you already run.
For a first line or cell, a working live board usually takes a few weeks, depending on how the machines expose their signals. We start with one area, prove it, then roll out to the rest of the floor.
Related
The other services in this section, and related pages from TCB Infotech.
No commitment. A practical first look at monitoring your floor.
