See where your plant loses time, shift by shift.

Operators log stops, scrap, rework and changeovers as they happen, by voice, photo or text. Shopfloor AI ranks the losses, groups what keeps repeating and checks whether each fix held.

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The problem

Why the biggest losses stay hidden

Every plant knows where it loses time, roughly. Few can say how much, on which line, and whether last month’s fix made a difference.

Losses are known, never measured

Everyone knows changeovers run long and the wrapper jams after a format change. Nobody has the minutes by line and shift to prove which one matters most.

Small losses never get written down

A ten-minute jam isn’t worth a form. Ten of them a week is most of a shift, and it never shows up in a report.

Fixes are never checked

A countermeasure is agreed in the meeting, and nobody looks at whether the problem came back. The same fault gets fixed five times.

How it works

From a stop on the line to a fix that held

  1. Log the loss where it happens

    Operators speak, photograph or type what stopped the line, what was scrapped or reworked, and how long a changeover took. A photo of the shift board adds target against actual for each hour.

    The Shopfloor AI home screen for Line 3, Filling, with the capture menu open: photo, scan, voice or text, over the shift's due checks and latest events.

  2. AI turns it into a loss record

    Each report becomes an event with its category, line, equipment and shift, and the minutes lost when the operator gives them. Shopfloor AI never estimates a time it wasn’t told.

    The shift review for Line 3: each voice note and photo already turned into a tagged event, such as a conveyor jam with 12 minutes lost, with two cards waiting for the operator to confirm the AI's reading.

  3. CI ranks the losses and fixes the cause

    The continuous-improvement dashboard ranks where the minutes went, with an estimated cost at your site’s rate, what keeps repeating, and the investigations under way, over a week up to a year.

    The continuous improvement dashboard for the last 30 days: 41 hours lost at an estimated 24,600 euros, filler bowl jams on Line 3 the biggest loss, the top five losses ranked by hours, and open investigations with their next step.

What you get

Loss tracking your CI team can act on

Every kind of loss in one place

Downtime, scrap and waste, rework and quality holds, changeovers, maintenance and material shortages, in categories your site can rename.

Minutes as stated, never guessed

Lost time comes from what operators say, attached to one event so nothing is counted twice, and supervisors can correct it.

A cost you can stand behind

Estimated cost is lost hours times your site’s hourly rate. No rate, no cost: the dashboard never shows a made-up number.

Repeat losses grouped

Similar losses on the same line and equipment are grouped once they happen three times over two days or more, with a rising, easing or stable trend.

Guided root-cause analysis

Why-why and fishbone investigations coach your CI team from evidence to a verified cause, and every recommendation becomes an owned action.

Fixes that are checked

Each fix is watched for 60 days and marked held or recurred, so the dashboard shows how many fixes actually stuck.

Questions

Scrap and changeover losses, answered

Other use cases run through the same app. See all use cases.

What counts as a changeover loss?

The time a line isn’t making good product while it switches from one run to the next: stopping, cleaning, swapping formats and parts, and the start-up rejects before the first good units. Shopfloor AI logs changeovers as their own loss category, next to downtime, scrap and rework.

How is lost time measured?

From what operators say in their reports. If someone says a jam cost 12 minutes, that’s recorded; if they don’t give a time, Shopfloor AI never guesses one. Supervisors can correct the minutes afterwards.

Does it calculate OEE?

No. Shopfloor AI doesn’t read machine counters. It captures the stops, scrap and changeovers people see, with their causes, which is the part OEE figures don’t explain. Photos of your shift board add target-versus-actual plan attainment.

How is the cost of a loss estimated?

Lost hours multiplied by one hourly rate you set for the site. If no rate is set, no cost is shown, so the dashboard never presents a made-up number.

Who runs the root-cause investigations?

Your continuous-improvement team starts them; supervisors and managers can follow them. Each investigation builds on the captures and your SOPs, and its recommendations become actions with owners.

How do we know a fix worked?

Every fix is watched for 60 days. If the same loss comes back on that line, the fix is marked as recurred; if it doesn’t, it’s marked as held, and the dashboard shows how many fixes held.

Pilot loss tracking on one line for 90 days

Measure how many hours of stops get logged with a cause, and how many of the fixes held.

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