Know why the line stopped before anyone calls you

When a line stops, the first hour usually goes into finding out what happened. Someone pulls CCTV. Someone checks the PLC screen. The operator who saw it is already on break.

The data is all there. It just lives in five different places.

Where it goes wrong today

• Stoppages get explained the next morning, from memory.
• Manual inspection gets tired by the end of a long shift.
• A motor runs hot for weeks before it finally trips.
• Leadership sees yesterday's report, not today's line.

What we set up

We build a live digital twin of the line, fed by your cameras, PLC signals and sensors. Each station shows its state as it happens.

At the stations that matter, vision inspection checks parts for defects, presence, position and codes. Thermal cameras watch motors, drives and panels for a slow rise in temperature. Every alert is linked to the video of that moment.

What changes

• A hot motor shows up as a warning weeks before it becomes a breakdown.
• Every part gets the same inspection on the night shift as on the day shift.
• Root cause takes minutes, because the data and the video sit together.
• You can try a layout change in the twin before you move a machine.
• Plant heads see every line, live, on their phone.

How we start

1. We walk the site with you and look at the cameras you already have.
2. We pick the two or three problems that cost you the most.
3. We run a pilot on one line, kitchen, building or route, with the numbers written down before we start.
4. If the numbers move, we roll out to the rest.

What we track with you

Before the pilot starts, we write down where these numbers stand today. Then we report against them every month.

• Unplanned downtime hours per month
• Defects caught at the station versus found downstream
• Time to spot and respond to a stoppage
• Thermal warnings that came before a failure
• OEE: availability, performance and quality