Operations directors need a performance picture that goes beyond individual machines and shifts. Shopfloor Copilot aggregates OEE, maintenance costs, and throughput data across every production line into a consolidated analytics view — connecting shopfloor performance directly to business outcomes.
Also see how Shopfloor Copilot serves other roles:
Operations directors face a fundamental challenge: the most important production data lives in machine PLCs and OPC UA servers — but it rarely reaches decision-makers in a usable form. Shopfloor Copilot bridges this gap by transforming raw OPC UA signal streams into executive-ready analytics: OEE trends, bottleneck analysis, comparative production line performance, and maintenance cost forecasts.
Compare OEE across all production lines side by side. Identify which lines consistently underperform and quantify the output gap vs. best-performing lines.
Week-over-week and month-over-month OEE trend with drill-down by Availability, Performance, and Quality component. Understand whether improvements are taking hold.
AI-identified production bottlenecks by line and station. Quantified throughput impact per bottleneck — prioritise improvement investments by ROI.
30-day maintenance window planning based on equipment health degradation models. Shift from reactive to scheduled maintenance — reduce emergency repair costs.
Downtime events tagged with cause code and duration. Calculate downtime cost per hour per line based on your throughput value. Justify maintenance investment in financial terms.
Aggregated shift performance across teams. Identify shift-level OEE variance — is Night Shift consistently underperforming Day Shift, and why?
Overall plant OEE across all lines, week-over-week OEE trend, maintenance cost as a percentage of asset replacement value, downtime cost per hour per line, planned vs. unplanned maintenance ratio, and throughput gap vs. theoretical capacity. These metrics connect shopfloor performance to financial outcomes.
Companies that implement real-time MES achieve 5–15% OEE improvement within 12 months. For a facility producing €5M/month, a 5% OEE improvement represents ~€250,000/year in additional output value — before reductions in scrap, maintenance costs, and energy waste.
Explore the prototype's the cross-line OEE benchmark, historical trend analysis, and bottleneck ROI quantification — the three analytics operations directors use most.
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