Factory Floor Kits

Decisions get made on numbers nobody trusts.

Each kit turns your own figures into one answer you can take into the next meeting. Answers in minutes. Free. No sales call.

All twelve kits are open today.

See the twelve kits

Three steps

  1. Pick the question your next meeting will ask.
  2. Enter the figures and answers you already have.
  3. Take the answer into the meeting, on screen or as a PDF by email.

Why these twelve

Four questions come up before money moves.

A plant manager, a maintenance lead and a CFO ask them in a different order, but they ask the same four. Each kit answers one part of one question, from figures you already have.

Which kit first?

Start where the next meeting will push.

Where are we losing?

Output, time and quality that leave the plant without a name. These four kits put a size on them: the OEE once every loss counts, the stops nobody named, the assets on the wrong strategy and the process that does not hold its limits.

Each drawing sketches the instrument the kit puts on screen. The kit fills it with your figures.

Sketch: one strip per shift, split into good parts, scrap and rework, speed loss, unlogged micro-stops and logged downtime.One bar per machine and shiftEarlyLateNightGood partsScrap and reworkSpeed lossUnlogged micro-stopsLogged downtime

The shift strips

OEE Reality Check

What is your OEE once every loss is counted, the unlogged short stops included?

For
Production and plant managers in machining and discrete manufacturing
You enter
For up to 12 machines and three shifts: planned time, logged downtime, unlogged micro-stops, ideal cycle time, total parts and good parts. Add what a good part is worth to you.
On screen
OEE with every loss counted beside the reported figure, the gap in points, the largest loss, the lost time as a euro band a year and a data grade A to D.
In the PDF, by email
OEE per machine and shift with the losses in hours and euros, the three machines to look at first, three ranked actions and questions for IT and OT.
Time
A few minutes

Read

Use the kit
Sketch: stop minutes per month for five cause families, the unknown family hatched.stop minutes per monthBreakdownChangeoverMaterialQualityUnknownhatched: stops without a cause

The Stop Board

Downtime Bleed

Which stops cost the most, and how many of them have no cause at all?

For
Production managers, shift leads and line owners
You enter
Stops per month and minutes per stop for five cause families, plus good parts per hour, margin per part and the crew on the line.
On screen
Lost minutes a month, the largest named family in euros, the share without a cause and a confidence grade A to D.
In the PDF, by email
Every family in euros, a Pareto, MTBF and MTTR, and three questions that give the unknown stops a name.
Time
A few minutes

Read

Use the kit
Sketch: six assets placed by time between failures and hours down per failure, across three strategy zones; one is ringed as off its strategy.Condition-basedFixed intervalRun to failureHours down per failureTime between failures, hours (MTBF)ring: asset off its strategy

The Plan Board

Maintenance Reality Check

Which assets need condition signals, which need a spare on the shelf, and which need a faster call-out?

For
Maintenance and reliability leads
You enter
For each of six assets: failures a year, hours to repair, hours until noticed, failure pattern, criticality, today's strategy and whether a spare is on the shelf. Add your loss per hour.
On screen
Each asset placed on the plan board, the stops in euros a year, availability, how many assets sit off strategy and a board grade A to D.
In the PDF, by email
The fleet table, criticality against strategy, where condition signals pay off, and spares and call-out.
Time
A few minutes

Read

Use the kit
Sketch: measured values stacked between the lower and upper limit jaws, with the mean and three-sigma lines and a scrap tray below.LSLUSLx̄−3σ+3σscrap tray · outside the jaws

The Jaws

Capability and Stability

Is your process stable enough for its Cpk to mean anything?

For
Quality engineers and process owners
You enter
The lower and upper limits, the nominal, the sampling rhythm and 25 to 200 values in production order. The values are not stored.
On screen
Cp, Cpk, Pp and Ppk, the expected share outside in ppm, four run rules, a stable or not stable verdict and a grade A to D.
In the PDF, by email
The control chart, all eight Nelson rules and the working.
Time
A few minutes

Read

Use the kit

What is it costing?

Losses in the units a board works with. One kit prices the waiting, the other finds the energy that never became a good part.

Sketch: cumulative loss over the months from today, with the loss before the decision hatched and the part still open shaded.decisiongone beforethe decisionopen after the decisioncumulative loss, index0122436months from today

The Decision Line

Cost of Inaction

What does another year of waiting cost, in units a CFO accepts?

For
Plant managers, and the finance lead who has to sign
You enter
A horizon of 12, 24 or 36 months, an improvement target and six plant figures: machines, utilisation, margin per hour, energy spend, unplanned downtime hours and scrap rate.
On screen
What is gone by the decision month and what stays open, as an index, the share of yearly margin and a data grade. No euros on screen.
In the PDF, by email
The curve in euros, the three loss streams ranked, where to look first and a budget class.
Time
A few minutes

Read

Use the kit
Sketch: a week of kWh flows into one machine and leaves as good parts, scrap and rework, and standby.One machine, one weekkWh / week inmachinegood partsscrap andreworkstandbykWh per good part, and the energy without one

The Flow Meter

Energy per Good Part

How many kWh does each good part take, and how much energy never becomes one?

For
Plant and energy managers
You enter
One machine over one representative week: kWh, parts produced, good parts, powered and producing hours, the standby share and your price per kWh.
On screen
kWh per good part, the kWh a week that never became a good part, the euro band a year behind them and a data grade A to D.
In the PDF, by email
Standby and scrap shown apart, and three or four first moves, each naming what to measure. An orientation, not an energy audit.
Time
A few minutes

Read

Use the kit

Are we ready?

What has to be in place before the first project: data, connections, scope. Four kits check the ground before anyone builds on it.

Sketch: a bar for each of eleven dimensions, the lowest marked as your number one gap, and a score ring out of 100.By dimensionyour number one gap11 dimensions/ 100score and band

Eleven dimensions

Factory Data Readiness

Where does your plant stand on factory data, and what should come first?

For
Plant, operations and IT leads in established brownfield plants
You enter
Answers to up to 31 questions across eleven dimensions, from machine connectivity to leadership and budget. The questions branch, so most plants answer 24 to 27.
On screen
A score out of 100 with its band, a bar for each dimension and your number one gap.
In the PDF, by email
The gaps to close first, and a plan in three phases: decide and own, instrument, then join and scale.
Time
About six minutes

Read

Use the kit
Sketch: four bays wired through their protocols to an edge node that only reads; the retrofit wire is dashed.BAY 1OPC UA · SBAY 2MQTT · SBAY 3Modbus RTU · MBAY 4I/O retrofit · Ledge node(reads only)one edge node per eight baysdashed: readable after a retrofit

The Patch Panel

Connectivity Explorer

Which protocol does each machine control speak, and which machines need a gateway or a retrofit?

For
OT, automation and IT leads planning machine connections
You enter
The control class of up to 16 machines, from OPC UA and MQTT to serial Modbus or no interface at all. Where you do not know a control, say so and the kit counts it apart.
On screen
How many machines are readable today, through a gateway or only after a retrofit, the integration effort as a range of days and a confidence grade A to D.
In the PDF, by email
Route, protocol and effort for each machine, an order of work, and the risks and questions for IT and OT. Effort is a planning range, not a quote.
Time
A few minutes

Read

Use the kit
Sketch: a counter lane with a reset at shift change, timestamps drifting from a reference clock, and a lane with gaps.countershift changeresettimestampsreference clockgapssampling: on change … 60 s

The Strip Chart

Signal Quality Check

Can your machine data carry a KPI?

For
Data, automation and quality engineers, before a KPI goes on a screen
You enter
Five answers about one tag: how often it is read, how the clock is synchronised, what the counter does at shift change, how tags are named and what is written when the link drops.
On screen
A grade A to D for timestamps, gaps, duplicates, counter resets, and units and names, then a signal grade, the KPIs it affects and the first fix.
In the PDF, by email
Every fix ranked by effort, the grade sheet, a clock-drift budget and questions for IT and OT.
Time
A few minutes

Read

Use the kit
Sketch: twelve machines on the floor, four inside a dashed fence, beside the pilot lengths and budget classes.Each square is a machinedashed: the fence, the pilot insidepilot length8 · 12 · 16 weeksbudget classS · M · La size, never a price

The Fence

Pilot Scoper

What should a first pilot cover, and how will you know it worked?

For
Whoever has to scope, staff and defend the first pilot
You enter
The machines on the floor and the ones inside the fence, the use cases, today's figures if you have them, where the data sits, who signs and which approvals are still open.
On screen
A pilot length of 8, 12 or 16 weeks, a budget class S, M or L (a size, never a price), the machines inside the fence and a fence grade A to D.
In the PDF, by email
A week-by-week plan, success criteria, roles per task, and the documents each approval needs, with the risks.
Time
A few minutes

Read

Use the kit

Are we allowed, and can it be funded?

Rules and money, settled before the project starts. One kit reads the regulation for your site, the other lists the programmes that fit.

Sketch: a plant hall inside the NIS2 scope line, four machines linked to a maker's cloud, an own rack or nobody, above a headcount ruler marked at 50 and 250.NIS2 SCOPEPLANT HALL Amaker's cloud,off-siteown racknobody holds it150250400headcount

The Site Plan

NIS2 and Data Act

Does NIS2 apply to your site, and what does the Data Act give you over your machine data?

Draft — pending legal review

For
Managing directors, plant managers and IT security leads in DACH and Belgium
You enter
Sector, turnover, headcount and country, who holds the data of four of your machines, and whether makers dial in for remote maintenance.
On screen
A NIS2 reading for your site, the likely entity class, how firm the reading is, and what the Data Act means for machines whose data you do not hold.
In the PDF, by email
The rule table, the ten measures of Art. 21(2), the reporting steps at 24 hours, 72 hours and one month, registration, and questions for each maker and for your lawyer. Orientation, not legal advice.
Time
About ten minutes
Use the kit
Sketch: a wall of pigeonholes by region and project type; envelopes mark programmes as open, ended or suspended, with a timeline from start to 18 months.DEATCHVLWABRdata infra.energyskillsdevelopmentstart+18 moopenendedsuspended

The Pigeonhole Wall

Funding Finder

Which public funding programmes fit a project like yours in DACH and Belgium?

Draft: programme list pending owner review

For
Managing directors and project leads in Germany, Austria, Switzerland and Belgium
You enter
Your region (and, in Germany, the Land), company size, project type and planned start.
On screen
The programme families that fit, each marked open, suspended or ended, with the funding body, the instrument, the rate and the date it was last checked.
In the PDF, by email
Each family in full with its link, the ended list, notes on combining programmes, what a first application asks for, and contacts.
Time
A few minutes
Use the kit

How it works

The answer is yours before anyone asks for an address.

  1. Answer the questions on screen. No account and no sign-up.
  2. See the result straight away, free.
  3. Want the deeper report? Enter a work email. The report you asked for is the only email you receive. No sequence follows.