Do we need an MES to use production analytics?

No. We can build analytics from ERP work order data, PLC signals, operator input tablets, or a combination. An MES provides the richest data, but useful production analytics can be built from whatever data sources you have today.

How do you handle manual production processes?

For manual operations without machine data, we deploy operator input stations \u2014 tablets or terminals at work centers where operators log starts, stops, counts, and scrap. Simple input, structured data.

Can this integrate with our existing MES?

Yes. We integrate with common MES platforms -- Plex, IQMS (DELMIAworks), and custom shop-floor systems. The analytics layer sits on top of whatever production data collection you already have.

What OEE improvement is realistic?

Manufacturers typically see 5\u201315% OEE improvement in the first year from visibility alone \u2014 before any process changes. The biggest gains come from reducing unplanned downtime and setup time, both of which become visible immediately with real-time tracking.

Data Analytics · Production

Know what\u2019s happening on the floor before the shift report tells you.

Production managers shouldn\u2019t discover yesterday\u2019s bottleneck in today\u2019s shift report. We build production analytics that track OEE, cycle times, scrap rates, and throughput in real time \u2014 so problems are identified when they can still be fixed, not documented after the fact.

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The Problem

Production Visibility That\u2019s Always a Shift Behind

✕OEE calculated manually at end-of-shift from paper logs and spreadsheet formulas

✕Scrap and rework tracked by the quality team but not connected to production line or machine data

✕Cycle time variation invisible \u2014 nobody knows which machines or operators are slower until throughput drops

✕Capacity planning based on theoretical rates, not actual measured performance

What We Deliver

Service Scope

Real-Time OEE Monitoring

Availability, performance, and quality tracked in real time for every production line and work center. OEE calculated automatically from machine data, MES, or operator input \u2014 not end-of-shift paperwork.

Cycle Time Analysis

Actual cycle times measured against standard times by machine, product, and operator. Identify variation patterns, slow-running jobs, and setup time opportunities.

Scrap & Rework Tracking

Scrap rates by product, machine, shift, and defect type. Connect scrap events to upstream process parameters to identify root causes, not just symptoms.

Bottleneck Identification

Automated detection of production bottlenecks based on throughput data, queue lengths, and utilization rates. See where production is constrained and quantify the capacity impact.

Schedule vs. Actual Analysis

Compare planned production schedule against actual completions in real time. Identify jobs that are behind schedule while there\u2019s still time to recover.

Shift & Operator Performance

Performance metrics by shift, crew, and operator. Identify training needs, best-practice patterns, and staffing optimization opportunities \u2014 with data, not opinions.

How We Work

Engagement Process

Production Data Audit

Inventory production data sources \u2014 MES, PLCs, paper logs, ERP work orders. Identify what\u2019s measured, what\u2019s missing, and what\u2019s measured but not used.

Metric Definition

Define OEE calculations, cycle time standards, scrap categories, and performance benchmarks. Align operations and production leadership on the definitions.

Data Pipeline & Dashboard Build

Build the data pipeline from production systems to analytics dashboards. Real-time for OEE and throughput, near-real-time for quality and scheduling metrics.

Deployment & Adoption

Deploy dashboards on shop-floor displays, supervisor tablets, and management desktops. Train production teams on using the data for shift management and continuous improvement.

Common Questions

Frequently Asked Questions

Work with Metrotechs

Every engagement starts with an assessment.

Not a proposal. Not a sales call. We tell you what we find, not what you want to hear. The Launchpad assessment maps your operation before any software work begins.

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