The Challenge: Manual Line Logs & Delayed Metrics
Manufacturing shift supervisors spent over 2 hours at the end of each shift manually collecting clipboard logs, line counter values, and downtime reasons into Excel. Management only received production reports 24 to 48 hours late, delaying operational interventions.
- Paper shift logs with illegible handwriting and missing downtime codes
- Discrepancies between raw machine counts and reported shift yield
- Leadership lacked real-time visibility into active bottleneck lines
- Excessive overtime spent on manual shift reconciliation reporting
The Eiront Solution: Real-Time Floor Ingestion & Analytics
Eiront deployed touchscreen operator portals linked to automated database ingestion pipelines and live Power BI executive dashboards.
Assess & Line Capture
Operators tap reason codes on touchscreen terminals during downtime events, logging micro-stoppages instantly.
Automate & Data Pipeline
Automated background workflows aggregate PLC machine pulse counts with operator downtime inputs every 15 minutes.
Advance & Live Insights
Real-time floor monitors display OEE (Overall Equipment Effectiveness) metrics, alerting plant managers to line anomalies.
Key System Features & Capabilities
Touchscreen Operator Portals
Simplified 2-tap downtime logging designed for fast shop-floor use.
Automated OEE Calculation
Computes Availability, Performance, and Quality metrics continuously.
Automated End-of-Shift Email
Generates formatted PDF summaries sent automatically to plant directors.
SQL Data Repository
Central historical database for multi-plant benchmarking and analysis.
Measurable Business Impact
Real-Time Response
Identified and resolved line stoppages 3x faster.
Supervisor Time Saved
Recaptured 15 hours per supervisor per week.
Yield Improvement
Overall plant throughput improved by 14% in 6 months.
We replaced paper clipboards with Eiront's automated system. Now our supervisors spend time fixing bottlenecks on the floor instead of typing numbers into spreadsheets.
