True process cost and time, from hard data
Cycle times, energy and machine hours recorded as they happen rather than taken from a standard. What a process actually costs to run, per part and per hour.
By job role
Engineer the process on measurements, not on opinion.
Most improvement work starts with an argument about what the problem is. Output IQ records what every machine and every process actually did, so the argument starts from the same set of numbers.
- No implementation fee
- Rolling monthly
- Thirty days to change your mind
- UK hosted
Downtime analysisLive
Lost time this week
All causes
13.5
Prev week16.1 hrs↓ 16.1% Week average14.8 hrs↓ 8.8%
Stops recorded
With a reason
148
Prev week131↑ 13.0% Unattributed4↑ 3600%
Parameters watched
Continuously
32
Machines24↑ 33.3% Alerting18↑ 77.8%
The problem
The cause of lost time is still a matter of opinion.
Ask three people why a line underperforms and you get three answers, all of them partly right and none of them measured. Improvement work then goes wherever the loudest case was made.
01
One bad shift becomes the whole story
A memorable failure outranks a persistent one every time. The thing that costs four hours a week for a year loses the argument to the thing that stopped the line once in March.
02
Equipment and process faults get mixed together
A machine that keeps tripping and a process that keeps drifting need completely different fixes. Without the readings behind each stop they arrive as the same line on a downtime report.
03
Nobody can prove a change worked
A change goes in, everyone agrees it feels better, and nothing is measured before or after. The next time budget is tight, that improvement has no evidence to defend it.
What you get
Efficiency from hard data, not guesswork.
Watch critical parameters as a process runs
Temperature, pressure, speed and vibration, sampled continuously against the window you set. You see a process drifting rather than discovering it drifted.
Root cause non conformance from real data
When something does not form, the conditions it was made in are already recorded. The investigation starts with the readings rather than with people trying to remember.
Engineer out stoppages using long run data
A single week is noise. Months of stops, ranked by cause and by hours, is a work programme, and it tells you which fix pays for itself first.
Find what works and repeat it on other lines
When one cell runs better than the others, the settings and conditions that made it are recorded. That is a spec to copy rather than a knack that leaves with a person.
Where the numbers come from
Four sources, one figure.
None of this is typed in by anybody. The number you look at is assembled from the parts of the business that already produce it.
The ERP
Orders, stock, purchasing and finance. What was sold, what it was quoted at and what was bought to make it.
Mobile job tracking
Jobs booked on and off from a phone or a tablet on the floor. Labour lands against the job as it happens, not on a timesheet at the end of the week.
Connected sensors
Power, vibration, heat, pressure and run hours, straight off the machine. Nothing to key in and nothing to remember.
Every stop, with the numbers behind it
Cause, duration, machine, job and the readings either side of it. Ranked by hours lost, so the improvement work goes where the money is.
Lost time this week 13.5 Down 16.1% on last week, all causes attributed
In practice
Measured, anonymised results will be published here as our first deployments report them. Nothing invented goes on this page in the meantime.
The rest of the business
The same feed, read a different way.
Questions
The ones engineers ask.
How granular is the data?
Readings are continuous rather than sampled on a shift basis, and every stop is timestamped to the second. You can look at a single event or at months of the same event.
Can I export it?
Yes. Data can be exported for your own analysis, and it stays yours. On exit you take it with you.
Does it work on old machines?
Yes. The sensors read the machine externally rather than through a control system, so age, make and model do not matter. If it draws current it can be monitored.
Can I set my own thresholds?
Yes, per machine and per parameter. Alerting is on every tier rather than gated to a higher plan.
Will it tell me the root cause?
It gives you the conditions and the sequence. The diagnosis is still yours, but you are working from a recording rather than from recollection.
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