Your machines already know. The office finds out tomorrow.
Most factories here run capable equipment and still manage it from a register and a phone call. The counters are on the machine, the reasons are in a supervisor's head, and the two meet in a spreadsheet a day later. We connect the equipment you already own to software that records output, stoppages and rejects as they happen — so a bad shift is something you handle during the shift.
What you get
| Line | Made / target |
|---|---|
| Line 1 | 1,840 / 2,000Running |
| Line 2Die change · 18 min | 1,190 / 2,000Stopped |
| Line 3 | 2,050 / 2,000Running |
Read from the machines you already own
Illustrative — not a customer's data
Readings pulled from the equipment you own
Counters, run states and alarms read from PLCs, drives, energy meters and SCADA over the protocols they already speak — Modbus, OPC UA, MQTT — or from an added sensor where a machine exposes nothing. Nothing is replaced to make this work.
Downtime with a reason on it
A stop is detected automatically, but the reason is chosen by the operator from your own list — die change, no material, power, breakdown. A stoppage count nobody can explain does not change a decision; one with reasons behind it tells you which machine to fix first.
Output measured against the plan
Produced against target per line and per shift, with rejects separated from good output. Availability, performance and quality are reported as the three separate numbers they are, because a single blended score hides which one moved.
The same numbers the office uses
Production is posted against work orders, materials and costing in the business system, so what the floor produced and what finance recorded are one figure rather than two that get argued about at month end.
| Line | Made / target |
|---|---|
| Line 1 | 1,840 / 2,000Running |
| Line 2Die change · 18 min | 1,190 / 2,000Stopped |
| Line 3 | 2,050 / 2,000Running |
Read from the machines you already own
Illustrative — not a customer's data
What it gives back
How it works today
A line stops and the office hears about it at the end of the shift. Nobody can say whether this month's losses came from breakdowns, material arriving late, or changeovers taking too long — so the same money goes out again next month.
With AIOSOL
Every stoppage carries its reason and its minutes. The three biggest losses of the month are a list you can read, and you can tell next month whether fixing the top one worked.
Money
The work behind it
The software above this equipment is work already delivered: production and inventory systems for machinery businesses, a technical catalogue for a grain-processing machinery supplier, and owner dashboards refreshing on a fixed cycle for people who are not on site. PLCs, HMIs, drives and servos are everyday vocabulary for this team, not something we would be learning on your project.
We do not sell or install the equipment
No hardware supply, no panel building, no field wiring, and no rewriting the safety or control logic inside your PLC — that is a licensed trade and it stays with your automation contractor. Our work reads what the machines already produce and builds the software above it. Where a machine genuinely exposes nothing, we will say so and tell you what a sensor would cost before anything is committed.
Frequently asked questions
Often yes. Age matters less than whether the machine exposes anything — many older machines have a PLC, a counter output or a contactor that can be read without touching the control logic. Where a machine truly exposes nothing, a small sensor on the output is usually enough. We check machine by machine and tell you which ones need something added before you commit to anything.
Reading data does not require stopping a line; it is done alongside the running control system, not inside it. Where a sensor has to be fitted, that machine needs a short window — usually a planned changeover or a maintenance day, arranged around your schedule rather than ours.
No. AIOSOL builds the software above the equipment, not the equipment trade. If a part is needed we will specify exactly what it has to do and you buy it from your own supplier — including the one you already use. Keeping those separate means our recommendation is never a sales pitch for a box.
Collection runs on the local network and keeps recording through an internet outage, syncing when the line comes back. Internet is needed for people who want to see the numbers from outside the factory, not for the factory to keep measuring itself.
Sectors that buy this
Related services
Not sure which one you need?
Tell us the problem you are trying to solve. We will say which service fits — or that none of them does.