Book a demo

Predictive maintenance in the factory: a shop floor that knows before the line stops

In a factory, the most expensive minute is a minute of unplanned downtime. BlueOperation reads machine health, energy and shop-floor traffic together; OEE is calculated live and maintenance is moved into planned stops.

Book a demo Follow a shift

Scroll: one shift from 06:10 to 14:00

Start of shift

Peak demand at start of shift

Two lines start up at the same time, and power demand approaches the contract limit. The shift supervisor delays one line by a few minutes, and the limit is never exceeded.

Compressed air

A compressor running all weekend gave away the leak

With no production, the compressor ran all weekend, a sign of an air leak. A work order is opened for the leak.

Predictive maintenance

The press gearbox speaks up before it fails

Vibration in a press gearbox has been rising for days. Maintenance is scheduled for the lunch break instead of an unplanned stop.

Forklift and pedestrian safety

A forklift entering the pedestrian crossing

Coming round a blind corner, a forklift enters a pedestrian crossing. The driver and the pedestrian are warned at the same moment, and a collision is avoided.

Pallet and material flow

Where's the mould? On the map.

The mould needed for a changeover isn't on its planned shelf. The map shows it on another shelf in the warehouse, and the delay stays at a few minutes.

Shift report

Shift closed, no unplanned downtime

The press maintenance was done during the lunch break, and the shift ended with no unplanned stops. Line performance and stop reasons are ready in the report.

Example scenario. Times, codes and values are illustrative.

Six factory areas, monitored on one platform

The same core, running on rules built for the shop floor's own machines, risks and teams.

Predictive maintenance

Presses, motors and gearboxes are monitored; when a fault is approaching, the maintenance job opens by itself.

OEE and line performance

Each line's performance is tracked live, and the reason for every stop is visible.

Forklift and pedestrian safety

Forklifts and pedestrians are tracked with precise positioning; a vehicle entering a pedestrian zone triggers an instant warning.

Compressed air and utilities

Compressor, boiler and cooling lines are monitored; leaks are caught from consumption deviation.

Energy management

Each line's consumption is tracked live; out-of-shift use and contract limit overruns show up in advance.

Pallet and material flow

The location of pallets, crates and moulds is on the map, so whatever you need is found right away.

We don't rip anything out; we build on top of the line's existing systems

PLCs, compressors and energy analyzers stay in place. BlueOperation reads them over their own protocols and brings them together in the same data model.

  • Presses, motors and gearboxes
  • PLC and line data
  • Compressors, boilers, cooling
  • Energy analyzers and MV
  • Forklift and pedestrian tags
  • Pallets, crates and moulds
  • Environmental sensors
  • Fire and cameras
  • Enterprise systems

Factory reference

Toyota and B/S/H, Türkiye

Site-wide location tracking, workplace safety and forklift-pedestrian collision prevention.

The detailed case study is in the Reference & Success Cases document.

Request the case study

The same core, at other facilities

  • Turkish State MintIstanbul
  • Alinma Bank HQRiyadh, Saudi Arabia

Production data doesn't have to leave the factory

Field devices are closed to outside access; data is sent only over an encrypted connection.

CloudCloud

Quick start, all facilities from a single center.

On-premiseOn-premise

Data stays on the factory's own servers.

EdgeEdge

Data is processed on site, close to the device.

HybridHybrid

Critical data stays on site, reporting is centralized.

Frequently asked questions

What does predictive maintenance software monitor in a factory?

Vibration, temperature and current trends on presses, motors and gearboxes. When a threshold is exceeded, a work order opens automatically; maintenance moves from unplanned downtime to a planned stop.

How is OEE calculated?

Availability, performance and quality are calculated live for each line, and the reason for every stop is visible.

How does forklift-pedestrian collision avoidance work?

Forklifts and pedestrians are tracked with precise positioning; when a vehicle enters a pedestrian zone, the driver and the pedestrian are warned instantly. This is how it runs at the Toyota and B/S/H plants.

Do we need to replace our existing PLCs?

No. BlueOperation is installed on top of your existing systems and reads them as they are; you don't have to remove anything.

Is data stored in the cloud?

The choice is yours: cloud, on-premise, edge or hybrid deployment. It can run without critical data leaving the facility.

Let's build a shift at your factory together

Share your list of lines and machines; we'll show you, on your own shop floor, which data turns into which action.

Book a demo Request the case study