Industries
Manufacturing & Production
Which line is losingperformance right now?
OEE figures, machine data and ERP metrics sit in separate systems. alpLytics connects these signals during the shift into one decision view that makes downtime, scrap and bottlenecks visible earlier.
The Reality in Production
Three systems, three truths. No reliable number.
Production managers know the problem: SAP delivers different OEE values than the MES, shift leaders maintain their own Excel sheets, and by the time the report is ready, the line has produced the next issue.
Data silos between ERP, MES and sensor systems
SAP, the MES layer and PLC data speak three different languages. Anyone who needs a valid OEE figure calculates it manually from spreadsheets. Daily. Error-prone. Time-delayed.
ASSESS maps all data sources. ENGINEER builds an automated pipeline that consolidates daily.
Manual shift reports without a data foundation
Shift logs are entered on paper or in local Excel files. Patterns across shifts, machines and products remain invisible. Until a major stoppage reveals the sum of many small warning signals.
DESIGN develops a unified capture logic. TRANSFER trains your team directly on the shop floor.
No early-warning system for equipment failures
Calendar-based maintenance instead of condition-based: failures are handled reactively, spare part inventories are oversized and major stops are identified too late. Predictive approaches fail due to poor sensor data history.
ASSESS evaluates sensor data quality. ENGINEER builds anomaly detection on your existing infrastructure.
Our Approach
From data chaos to reliable production KPIs.
The ADET framework describes how alpLytics works. The shift loop shows how production decisions flow. Both work together: ADET builds the infrastructure, the loop uses it every day.
Understanding production data
We analyse your ERP, MES and sensor data for completeness, consistency and usability. Interviews with shift leaders and production planners reveal which KPIs are genuinely decision-relevant and which have just grown historically.
Data audit report with OEE baseline and recommendations
Architecture for the shop floor
We design a data pipeline that automatically consolidates your source data. No proprietary platforms, no complex middleware stacks. The design prioritises robustness over perfection. It must work during the shift.
Technical concept incl. data model, tool recommendation and integration plan
Implementation with production context
Building the pipelines, OEE data model and dashboard development. We work iteratively in 2-week cycles, testing every step with real production data. No big-bang rollout. Each iteration delivers immediately usable results.
Real-time OEE dashboard, automated shift report, anomaly alerts
Handover to the production team
Documentation in plain language, no IT expertise required. Shift leaders, production planners and plant managers receive separate training formats. We remain available for four weeks after go-live.
Operations manual, training materials, 4-week hypercare period
Understanding production data
We analyse your ERP, MES and sensor data for completeness, consistency and usability. Interviews with shift leaders and production planners reveal which KPIs are genuinely decision-relevant and which have just grown historically.
Data audit report with OEE baseline and recommendations
Architecture for the shop floor
We design a data pipeline that automatically consolidates your source data. No proprietary platforms, no complex middleware stacks. The design prioritises robustness over perfection. It must work during the shift.
Technical concept incl. data model, tool recommendation and integration plan
Implementation with production context
Building the pipelines, OEE data model and dashboard development. We work iteratively in 2-week cycles, testing every step with real production data. No big-bang rollout. Each iteration delivers immediately usable results.
Real-time OEE dashboard, automated shift report, anomaly alerts
Handover to the production team
Documentation in plain language, no IT expertise required. Shift leaders, production planners and plant managers receive separate training formats. We remain available for four weeks after go-live.
Operations manual, training materials, 4-week hypercare period
Results from the Field
What changes in manufacturing operations.
Shift reports that previously required 45 minutes of manual work are now generated automatically from production data.
Automatic alerts allow shift management to detect critical deviations before an unplanned stoppage occurs.
Clear visibility into availability, performance and quality enables targeted action instead of gut-feel decisions.
Shift reports were assembled manually from SAP and MES every day, taking 45 minutes and arriving too late.
alpLytics built an integrated OEE pipeline that consolidates automatically by 06:00 each day.
The plant management team of a Tyrolean supplier with 150 employees receives a valid shift report every morning without manual preparation.
Shopfloor Decision Loop
Data only helps when it reaches the right person at the right moment.
The loop shows how a machine impulse becomes a prioritised measure and how each shift improves the next.
Priority
OEE, cycle, scrap and downtime are assessed against targets and historical patterns.
OEE Performance Split
Availability, performance and quality become a decision.
OEE is only valuable when the causes behind it become visible. The split shows which factor is really slowing the shift right now.
Line 3 Packaging
Click an OEE factor to reveal cause, data sources and measure.
Cycle time losses from undocumented micro-stops under 5 minutes
Micro-stop aggregation and cycle deviation cockpit per asset
3 to 5 % potential through visible micro-stops
Relevant Services
What we bring to your manufacturing operation.
Next Step
Which production KPI costs you time every day?
In 30 minutes we will show you whether and how we can solve your specific situation. No sales pitch, just a clear look at your data landscape.