The 500 biggest companies in the world lose $1.4 trillion a year to unplanned downtime

We build maintenance, plant knowledge, purchasing and safety records into the ERP, maintenance and quality systems you already run.

Lines running

11 of 12

Line 4 paused for a planned die change

Work orders open

38

Six opened today when a sensor crossed its limit

Next likely failure

Press 4

Bearing temperature rising, inspect within 3 days

Spare parts below minimum

22

Reorders drafted for 19 of them

65% of manufacturers said attracting and retaining talent is their primary business challenge

The people who know the machines are leaving faster than they are replaced. We build the record of what they know, searchable at the machine.

Where the line loses its hours

Manufacturers, process plants, mines and quarries, and the suppliers and maintenance firms around them.

77%

Hard to hire

of manufacturers expected ongoing difficulty attracting and keeping workers

18.3%

Non-fatal accidents

of all those at work happen in manufacturing

13.8%

Fatal accidents

of all those at work happen in manufacturing

1.9 million jobs

in manufacturing could go unfilled by 2033

  • 77%

    Hard to hire

    of manufacturers expected ongoing difficulty attracting and keeping workers

  • 18.3%

    Non-fatal accidents

    of all those at work happen in manufacturing

  • 13.8%

    Fatal accidents

    of all those at work happen in manufacturing

  • 1.9 million jobs

    in manufacturing could go unfilled by 2033

Every machine and every order, live on one floor plan

Machine states, alarms and work orders read from the sensors and the maintenance system you already run. The next likely failure is flagged while the line still runs, and the procedure, the permit and the part are at the machine.

Shift BLive, Monday 07:52

Paused

Press 4

Current job
Door panels, 2,000 pieces
Operator
M. Novak
Back on the line
09:40, after the die change
  • Die change procedure, 14 steps
  • Permit to work valid until 18:00

Running

Machining centre 2

Gearbox housings, 400 pieces

D. Ionescu

Paused

Press 4

Die change, back on the line at 09:40

M. Novak

Fault

Welding cell 1

Wire feed stopped, work order opened

L. Moreau

Running

Laser cutter

Brackets from 8 mm plate

S. Varga

Every spare part where the next job needs it

Parts held by how critical they are, reserved before the job and reordered before they run out. Supplier confirmations and dates are read into the ERP, so a late delivery shows against the plan before it stops a line.

The store todaySpare parts, bay A

  • Deliveries expected today14
  • Picked for work orders37
  • Late against the plan2
  • Below their minimum22
  • Reorders drafted19
  • Locations used85 of 120

Racks by fill120 locations

38%Full
33%Part full
29%Empty

Bay A, racks 1 to 12Level 1 at the floor

  • Full
  • Part full
  • Empty

How we work

From the first call to software that runs, in six steps, with the price agreed before any work starts.

  1. First call

    Talk through how maintenance, purchasing, quality or safety run today, and where the hours and the output go.

  2. Operations map

    A written map of every system, handoff and manual step, from the alarm or the purchase order to the closed work order or the paid invoice.

  3. The plan

    What we build first, what it replaces and what it costs, agreed before any work starts. It usually starts with unplanned downtime on the lines that cost most to stop.

  4. The build

    Built inside your ERP, maintenance system, machine data and quality records, without changing the control systems that run the plant.

  5. Going live

    Reviewed with the maintenance, production and quality leads, then switched on one line or one site at a time.

  6. Running

    We watch every run, fix what breaks and add the next piece when you are ready.

What stays with people

Anything that touches the machines, safety or quality stays with your engineers: what gets stopped, repaired, released or signed off. The software keeps the schedules, the checks and the record, and the models read the sensor trends, the manuals and the supplier documents and say what they see.

Built on what you already run

ERP, the maintenance system, sensors and machine alarms, quality and safety systems, supplier portals, spreadsheets and email.

Bring the line that costs most when it stops. Leave with a written map of what stops it.

On the first call we go through how maintenance and purchasing run on that line with you: which systems it touches, where the work waits and which steps are done by hand. The call ends with a written map of what we would build first, and the price is agreed in the plan before any work starts.

Frequently asked questions

Do you replace our ERP or maintenance system?

No. We build on top of the systems you already run and connect them, so your people keep working where they work today.

Does it connect to our machines and control systems?

It reads what your sensors, alarms and historians already record. It does not change how the machines are controlled, and anything that would goes to an engineer.

Who sees our production data?

Only the engineers on your project, and only in the systems you open for them. You decide what each automation can read and what it can change, and every run is logged.

How soon does something run, and what does it cost?

It depends on the work. The plan names what goes live first, when, and the price, before any work starts.

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