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Industry 4.0 · Real-time manufacturing intelligence

See every machine.
Know every second.

Turn live shop-floor data into faster decisions, higher utilization and predictable production.

Explore the platform
  • Live machine data
  • Real-time OEE
  • Production visibility

Digital twin of plant 01: 18 of 22 machines running, 2 idle, 1 down, 1 in maintenance.

Live

Shop floor overview

Plant
PLANT 01
Shift
A
Time
13:12:07
OEE
0.0%
A × P × Q
Availability
0.0%
Performance
0.0%
Quality
0.0%
Machines running
0/ 22
2 idle · 1 down · 1 PM
Production today
0/ 10,000
Parts · all lines
Downtime
0 min
Avg per machine · this shift

OEE · Plant

Shift A
OEE0.0%Target 85%
  • Availability91.6%
  • Performance82.7%
  • Quality98.8%

Output · Shift A

Target 1,250 / h
3156309451.3k06:0007:0008:0009:0010:0011:0012:0013:00

Machine status

LINE 03
  • CNC-01Running
    19.9s
  • CNC-02Running
    31.3s
  • CNC-03Idle
    —
  • CNC-04Downtime
    —
  • CNC-05Running
    11.0s
  • CNC-06Maintenance
    —

Shift timeline

now 13:12
06:0007:0008:0009:0010:0011:0012:0013:0014:00
CNC-01
CNC-02
CNC-03
CNC-04
CNC-05
CNC-06
  • Running
  • Idle
  • Downtime
  • Maintenance

Floor map

22 machines
LINE 01 · VMC
LINE 02 · SPM
LINE 03 · CNC
LINE 04 · HMC
LINE 05 · GRD

Event stream

Live
  1. 13:12:07CNC-04Coolant pressure low · 2.1 bar · stop ongoing
  2. 13:12:04CNC-05Cycle complete · 11.0 s
  3. 13:12:01VMC-03State → RUNNING · material loaded
  4. 13:11:58CNC-02Cycle complete · 31.2 s
System onlineLast update 00:00:021,284 signals / min

Built for plants like these

  • Precision Components, Precision machining
  • Advanced Motion, Motors and pumps
  • Driveline Components, Automotive Tier 1
  • Hydraulic Systems, Hydraulics
  • Industrial Mfg., Heavy engineering
  • Drivetrain Group, Renewables

The problem

Most factories fly blind between shifts.

Production management still runs on information that is written down after the fact. By the time it reaches a manager, the shift it describes is over.

Where the numbers usually come from

  • Manual reporting
  • Delayed information
  • Spreadsheet tracking
  • Operator updates
  • End-of-shift reports
  • Unclear downtime reasons
  • 06:00Shift A14:00

    Production data arrives too late

    By the time the end-of-shift report is typed up, the shift it describes is over and the losses are already booked.

  • Reported3 stops
    Actual7 stops

    Downtime disappears between reports

    Short stops, waits and micro-stoppages never make it onto paper. They add up to hours nobody can see.

  • Planned capacityAchieved
    • CNC-01
      93%
    • CNC-02
      89%
    • CNC-04
      66%

    Planning decisions rely on assumptions

    Capacity is planned on standard cycle times, not on what each machine is really achieving today.

  • Sheet
    Board
    Call
    Chat
    One view

    Managers lack one live view

    Spreadsheets, whiteboards, phone calls and operator updates each tell a different version of the same shift.

Platform

From machine signal to production decision.

Concept Digital Factory is the path from an electrical signal on the floor to a decision in the office, shortened to seconds.

  1. Machine

    01

    Machine signals are captured directly from the control, the sensor or the operator terminal.

    • State
    • Cycle
    • Alarm

  2. Live data

    02

    Production data becomes visible in real time, machine by machine, without anyone typing it in.

    • ≤ 1 s
    • Timestamped

  3. Analytics

    03

    The system calculates meaningful metrics: OEE, cycle deviation, downtime by reason, output against plan.

    • OEE
    • Loss
    • ETA

  4. Insight

    04

    Managers and supervisors see what is happening, where, and why, on one screen.

    • Who
    • Where
    • Why

  5. Action

    05

    Teams act before small problems become major losses.

    • Alert
    • Re-plan
    • Fix

The platform

Four modules. One live data model.

Each module answers a different question about the same shift. They share the machine data, the reason codes and the clock, so the numbers agree.

Platform overview

Live shop floor

Your whole shop floor.
On one screen.

Every machine, its current state and its numbers for the shift. Hover a machine to find it on the floor plan.

Explore machine monitoring

Plant map

Live
LINE 01 · VMC
01
02
03
04
LINE 02 · SPM
01
02
03
04
05
06
LINE 03 · CNC
01
02
03
04
05
06
LINE 04 · HMC
01
02
03
LINE 05 · GRD
01
02
03
  • Running
  • Idle
  • Downtime
  • Maintenance

18 running · 2 idle · 1 down · 1 PM

Hover a card to locate it on the plant map

  • CNC-01

    Housing HX-220 · #4822

    Running
    Cycle time
    19.9s+7.6%
    Target cycle
    18.5s
    Output
    1,248 / 1,400
    OEE
    88.3%
    Downtime
    18 min
    R. Patel · since 08:24In cycle

  • CNC-02

    Shaft SR-18 · #4825

    Running
    Cycle time
    31.3s+11.8%
    Target cycle
    28.0s
    Output
    812 / 900
    OEE
    87.3%
    Downtime
    9 min
    M. Okafor · since 10:39In cycle

  • CNC-03

    Flange FL-90 · #4831

    Idle
    Cycle time
    —
    Target cycle
    19.0s
    Output
    1,105 / 1,300
    OEE
    80.0%
    Downtime
    55 min
    S. Nakamura · since 12:58Waiting for material

  • CNC-04

    Valve body VB-7 · #4834

    Downtime
    Cycle time
    —
    Target cycle
    27.5s
    Output
    640 / 1,000
    OEE
    66.2%
    Downtime
    96 min
    L. Fischer · since 12:36Coolant pressure low

  • CNC-05

    Bracket BK-31 · #4840

    Running
    Cycle time
    11.0s+5.8%
    Target cycle
    10.4s
    Output
    2,310 / 2,400
    OEE
    92.1%
    Downtime
    8 min
    A. Costa · since 11:26In cycle

  • CNC-06

    Impeller IM-5 · #4812

    Maintenance
    Cycle time
    —
    Target cycle
    52.0s
    Output
    305 / 600
    OEE
    60.6%
    Downtime
    152 min
    J. Brennan · since 10:40Planned PM — spindle

OEE intelligence

Know whether your target is being lost to availability, performance or quality.

OEE is one number. Concept Digital Factory shows the three numbers behind it and the minutes behind each of those, per machine, per shift, as it happens.

Explore OEE intelligence
  1. Planned production time100.0%

    432 min elapsed

  2. After availability loss−8.4 pts91.6%

    Stops, waits, changeovers · 36 min / machine

  3. After performance loss−15.8 pts75.8%

    Slow cycles and micro-stops

  4. After quality loss−0.9 pts74.8%

    Scrap and rework

Plant OEE · Shift ABenchmark 85%
OEE0.0%Target 85%
  • 0.0%

    Availability

  • 0.0%

    Performance

  • 0.0%

    Quality

Digital factory

Every physical machine has a digital story.

Concept Digital Factory keeps a live digital counterpart of each machine on the floor: what it is doing, what it has done and what it should be doing next.

  • Solid = the physical machine on the floor
  • Wireframe = its digital twin in Concept Digital Factory
  • Packets = state, cycle and count signals, every second

  1. Physical machine

    CNC-04 · Line 03

    • STATE
    • CYCLE
    • COUNT

  2. Digital signal

    PLC · sensor · terminal

    • 1 – 5 s
    • TIMESTAMPED

  3. Data layer

    Time-series with context

    • ORDER
    • OPERATOR
    • SHIFT

  4. Production intelligence

    OEE · downtime · plan

    • LIVE
    • HISTORY

Industries

Built for the machines that make everything else.

Concept Digital Factory is used where machining time is the scarce resource and every minute of the shift has to be accounted for.

All industries

  1. Automotive

    Tier-1 and Tier-2 suppliers running high-mix, high-volume machining against strict takt times.

    CNC · VMC · Transfer lines

  2. Hydraulics

    Valve bodies, manifolds and cylinders where bore tolerance and cycle discipline decide margin.

    HMC · Deep-hole · Honing

  3. Motors & Pumps

    Housings, shafts and impellers across turning, milling and balancing cells.

    Turning · 5-axis · Balancing

  4. Marine

    Large, low-volume components where every hour of spindle time is expensive.

    Boring mills · Large VTL

  5. Heavy Engineering

    Fabrication and machining of structural components with long cycles and long changeovers.

    Gantry · Plate · Welding cells

  6. Renewables

    Gearbox, hub and bearing components with demanding quality documentation.

    Gear grinding · Large turning

  7. Precision Components

    Job shops and contract manufacturers competing on utilization and on-time delivery.

    Swiss · CNC · Grinding

Why Concept Digital Factory

Built for the floor.
Trusted in the boardroom.

A production system is judged by two audiences: the people who run the machines and the people who answer for the numbers. Concept Digital Factory gives both the same truth.

About Concept Digital Factory

  1. Real-time visibility

    Machine state, output and losses as they happen. Not as they were remembered.

  2. Less manual reporting

    The data is captured at the machine. Nobody fills in a sheet at the end of the shift.

  3. Faster decisions

    A supervisor sees a stop within seconds and knows where to go first.

  4. Higher machine utilization

    Idle capacity and bottlenecks are visible, so the next improvement is obvious.

  5. Better production predictability

    Estimated completion moves with live output, so promises to customers hold.

  6. Clear accountability

    One timeline per machine. The same numbers on the floor and in the boardroom.

  1. Downtime reasons
    BeforeReconstructed at the end of the shift
    With CDFTimestamped at the machine, coded in two taps
  2. OEE
    BeforeA monthly spreadsheet nobody trusts
    With CDFLive, per machine, per shift, with minutes behind each point
  3. Planning
    BeforeStandard times from the ERP
    With CDFReal capacity with ETAs that move with output
  4. Reporting
    Before30 minutes of typing per shift
    With CDFNone. The screen is the report
  5. Decisions
    BeforeTomorrow morning
    With CDFWithin seconds of the event

Key figures

Seconds
from machine event to visibility

Not end of shift. Not tomorrow.

0%
production visibility

Captured automatically, without manual reporting.

0
live source of truth

The same numbers for the floor and the boardroom.

24/7
shop-floor monitoring

Every shift, every machine, every second.

From the floor

What changes when the numbers are live.

Illustrative accounts from plants running real-time monitoring, across six sectors. Replace with approved customer quotes before launch.

  • Precision Components

    “We used to find out about a bad shift the next morning. Now the supervisor sees a machine stop within seconds and the reason is already on the screen.”

    Plant Manager

    Precision Components Ltd.

    +11%

    OEE in one quarter

  • Motors & Pumps

    “The planning board finally reflects what the machines are actually doing. Estimated completion moves with real output, not with what someone wrote on a whiteboard.”

    Head of Production

    Advanced Motion Systems

    −38%

    manual reporting time

  • Heavy Engineering

    “Downtime is one honest number now. When we argue about a machine, we argue about the timeline, not about whose report is right.”

    Operations Director

    Industrial Manufacturing Co.

    22

    machines on one screen

  • Automotive

    “Cycle drift used to surface at the end of the month. We caught six percent on two machines in the first week and traced it to one tool-change routine.”

    Manufacturing Engineer

    Driveline Components Ltd.

    6%

    drift caught in week 1

  • Hydraulics

    “I stopped asking for the morning report. I open the same screen the shift supervisor has, and we talk about what to fix instead of what happened.”

    Managing Director

    Hydraulic Systems Engineering

    0

    end-of-shift reports

  • Renewables

    “Traceability used to be a week of collecting sheets before an audit. Now every serial number already has its machine, tool and operator attached.”

    Quality Manager

    Drivetrain Components Group

    100%

    serial traceability

Get started

Your machines are already generating the data.

Start turning every production signal into a better decision.

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  • Real machine data, no slides
  • Reply within one working day
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