Solution · Production & Process Analytics
Where the time and the parts went.
Shift-based production and downtime analysis that works across controller brands — and shows n/c (not captured) instead of inventing a number when a value is not connected.
The problem
What you are up against.
- 01
OEE that quietly assumes 100 % quality because nobody counts rejects.
- 02
Shift calendars with breaks, overnight shifts and holidays that the analytics tool cannot represent.
- 03
Reports that cannot be exported exactly as they appear on screen.
The approach
Assign once, evaluate everywhere
For each machine you assign once which value is the machine state, the part counter, the cycle signal, the program name or the alarm. Every evaluation — state, shifts, parts, jobs, downtime and OEE — builds on that, so the same analysis runs on a Sinumerik, a Haas and a grinder without a controller connection.
Shifts as they really are
Your time zone, shifts across midnight, breaks as real breaks, holidays. Every change to the shift calendar carries through to all evaluations. Utilisation works before parts counting is set up — measured against planned time or the full calendar, broken down by machine state.
Reports that export themselves
OEE, utilisation, downtime, parts and alarms over real time ranges, per shift or day, for the whole fleet or one machine — with target bands, a clear note where data is incomplete, and CSV export of exactly what is on screen. Downtime is ranked by cause, shows whether a few causes dominate, and can be classified in bulk straight from the event list.
What we use
- Machine state from the controller — or from a retrofit sensor where there is none
- Part counters and cycle signal
- Program name to recognise jobs
- Alarms with the controller's text
- Target cycle times from your operations list
What you get
- OEE, availability, performance and utilisation per shift, day and machine
- Downtime by cause, with a simple way to classify it
- Parts with a record of every correction; jobs with pace and expected finish
- CSV export of every report and of the daily production sheet
Tested on
- LabThree-machine lab fleet with shift calendar, downtime classification and alarm archive
- LabA complete alarm archive with the controller's original text
Tested on the lab machines in Tuttlingen — proof that it works, not customer references.
Next step
Bring production & process analytics to your machines.
We start with one machine and the signals it already has. Tell us the controller and the question, and we will tell you what the first weeks look like.