Factory Data Control Tower
Real-time visibility from ERP to shop floor. Production data, QC analytics, and predictive maintenance in 30 days.
The Problem
Production, QC, Downtime & Inventory Still Living in Excel
ERP systems sit isolated from shop-floor realities. Production schedules don't sync with actual output. QC data lives in spreadsheets. Downtime reasons are captured manually, weeks later. Inventory positions are guesses. Operations leaders have no visibility into bottlenecks, yield loss, or margin impact in real time.
Actual vs. planned output is a mystery until month-end.
QC failures detected late. Root cause analysis is impossible.
Line stoppages aren't tracked. Recovery times are never optimized.
What We Build
Factory Data Control Tower
Real-time dashboards: production rates, OEE by line, yield %, inventory levels, and margin impact per SKU.
QC & Defect Analytics
Automated QC data ingestion, defect trending, root-cause clustering, and SPC charts for quality gates.
Predictive Maintenance Starter
Machine health signals, anomaly detection, and downtime prediction. Move from reactive to preventive.
Downtime Tracking & Analysis
Automated downtime capture, reason classification, and recovery time benchmarking by line and shift.
ERP-to-Shop-Floor Integration
Bi-directional sync with SAP/Oracle/NetSuite. Real-time inventory, production scheduling, and fulfillment visibility.
Plant-Wide Benchmarking
Multi-plant dashboards, shift-over-shift trending, and performance competitions to drive operational excellence.
Outcomes You'll See
30-Day Control Tower Go-Live
Dashboards live and actionable in 4 weeks. Real-time production, QC, and downtime visibility for operations leaders.
OEE Improvement (5–15%)
Eliminate downtime blindspots. Predictive alerts catch issues before they cascade.
Yield Loss Quantification
Pinpoint where scrap happens. Correlate QC failures with production conditions and machine health.
Inventory Accuracy (95%+)
Real-time sync between ERP and floor. No more ghost inventory or emergency orders.