Know when a planned job is not running
The schedule says the press is on job 40118. The machine says it has drawn nothing for forty minutes. You see the gap between those two while there is still a shift left to save it.
By job role
Run the floor on what is happening, not on what was reported.
By the time a stoppage reaches a production meeting the shift has gone. Output IQ shows every machine running, idle or down as it happens, against the job it is supposed to be on.
- No implementation fee
- Rolling monthly
- Thirty days to change your mind
- UK hosted
Live floorLive
Machines running
Whole site
18
Capacity24 assets↓ 25.0% Prev shift16 assets↑ 12.5%
Idle right now
No job loaded
4
Prev shift2 assets↑ 100.0% Shift average3 assets↑ 33.3%
Down right now
Unplanned
2
Prev shift1 asset↑ 100.0% Week average3 assets↓ 33.3%
The problem
The plan and the floor stop matching, and nobody knows when.
A schedule is a promise made yesterday. What is actually running, what is sat waiting and what has quietly stopped is a different picture, and it usually arrives after the shift it belonged to.
01
You hear about a stoppage at the end of the shift
By then the hours are gone, the job is late and the only thing left to do is explain it. A machine that stops at ten past nine should be on somebody's screen at eleven past.
02
Idle time is invisible until the numbers arrive
A machine sat powered on with no job loaded looks exactly like a machine working, from anywhere but next to it. It is paid for either way.
03
The plan assumes cycle times nobody has checked
Scheduling runs on standards. Real cycle times drift with tooling, material and operator, so the plan is optimistic in places nobody has measured.
What you get
Full control of your shop floor in real time.
Spot kit powered on but making nothing
Idle draw and running draw look nothing alike to a sensor. Machines sat warm and waiting are separated from machines actually producing, continuously and without anyone walking the floor.
Catch machines run outside the plan
Work run off plan costs twice, once in the hours and again in the rework. Anything running that was not scheduled shows up as it starts rather than at the end of the week.
See machines sitting idle mid shift
Not every gap is a breakdown. Waiting on material, waiting on a setter and waiting on a decision all look like idle time, and all of them are recoverable once you can see them.
Get live alerts on any unusual pattern
Thresholds you set, on the machines you choose, sent to the floor, to a manager or to both. The point is to shorten the gap between something going wrong and somebody knowing.
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.
One live picture of the floor
Every machine, every job, every stoppage, joined and timestamped. No walk round, no whiteboard and no waiting for the shift to end.
Machines running now 18 Of 24 assets, updated continuously
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 production managers ask.
Do I need to change how we schedule?
No. Output IQ reads what the machines are doing and compares it to the plan you already run. If you want the scheduling in the same system it is there, but it is not a condition of getting the visibility.
What counts as a stoppage?
You decide. The threshold is set per machine, so a press that pauses for eight seconds between strokes is not logged as down while a machine idle for four minutes is.
Will operators have to log everything?
No. The machine reports itself. The only interaction is confirming a reason when something has already stopped, which is one tap on a terminal.
Can I see more than one site?
Yes. Machines, areas and sites roll up into one view, and you can drill from the group figure down to a single asset.
How quickly does the floor view update?
Continuously. Readings arrive from the machine rather than from a person, so there is nothing to wait for and nothing to key in.
Get started
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Explore how Output IQ can empower your business, from automated ERP and MRP to live data analysis and sensors. Service before Software.