A12 · press
RUNNING
More capacity,
without more machines.
Find the losses hidden across mixed-age machines, manual processes and disconnected systems. That includes existing MES and ERP environments. Start with one defined problem, prove the value, then scale only what works. No rip-and-replace programme.
CUSTOMER STORY
Capacity hidden in hundreds of small things.
One precision manufacturer unlocked a year of capacity without buying a single new machine. It did not come from one big fix. It came from hundreds of small things made visible for the first time: a machine that would not restart after an alarm turned out to be a door not closed properly, sorted on the spot instead of shutting down and waiting for maintenance.
+10 machinesof capacity unlocked from the floor they already had
~$3Mof additional annual capacity
100%of manual data collection eliminated
“People who’ve worked here for 30 years learned about issues they didn’t know existed.”
up to15%improvement to OEE
up to90%reduction in manual data collection
typically20%reduction in maintenance call-outs
can be100%on-premise · your data, your walls
Ranges observed across DataQI deployments. Your own figure depends on your constraint, your baseline and whether there is demand for the extra output.
Where it hides. Four production losses worth making measurable.
DataQI connects what is already there: new machines, older assets, manual work and business systems. An improvement team can see where output, quality and time are being lost.
01
Reduce downtime
The stops that hide as workarounds, the waits for a fix, the failures nobody saw coming. We pin each one to a root cause and design it out.
B04 · CNC
STOPPED
L3 · assembly
RUNNING
02
Improve quality
Catch defects at the source and flag drift before it becomes scrap, so your output isn't spent making parts you'll only throw away.
batch 411.1%
batch 421.6%
batch 432.3%
batch 443.1%
still in tolerance · flagged before it isn't
03
Optimise productivity
The idle time, awkward steps and quiet bottlenecks that hold a line below its pace. exposed, costed, and turned into a case for closing them.
2 · seat clips6s
3 · fit lid clip5–30s
4 · press tabs5s
6 · refill binidle
step 3 variability 76% · invisible on a walkaround
04
Keep the knowledge
Thirty years of experience is walking out of the door. We put it behind a single question, so a new starter can draw on years they were never around for.
B07 spindle is noisy on start-up. What first?
Four past entries match. Every one was drawbar pressure, not the spindle. Check that before escalating.
4 maintenance records · B07 · 2019–2025
Two versions of the same day.
The floor doesn't change. What the production manager can see does.
07:40
A walk, coffee going cold
Machines running, machines stopped, lights flashing. A few words with whoever's nearby, and no real way to know what actually matters today.
09:15
A line's been down an hour
Nobody flagged it. Now it's a scramble to work out why, long after the output was already lost.
11:30
Stand-up runs on opinion
The loudest problem gets the attention, not the biggest. Effort goes where the noise is, not where the loss is.
14:00
Chasing numbers by hand
Time spent collecting figures that should already exist, keyed into a spreadsheet that's out of date by the time anyone reads it.
16:45
Home, none the wiser
Leaving without knowing whether today's output will hit the commitments the floor made. Tomorrow starts the same way.
07:40
Coffee still hot, dashboard open
A live view of the whole site against the work orders that matter today. The picture is there before the walk even starts.
08:05
One cell is dragging availability
Drill in, see the cause, fix it before stand-up. The problem that would have defined the day is gone by nine.
11:30
Stand-up runs on evidence
Losses ranked by impact. The team works the biggest one first, with the data to prove it actually moved.
14:00
The numbers are already there
Collection is automatic, so the afternoon goes on improving the line rather than measuring it.
16:45
Home, knowing where it landed
Today's output is clear, and so is tomorrow's focus. The firefighting has given way to improvement.
We run a pilot on a subset of your machines, for free.
We connect DataQI to a subset of your machines, capture real floor data, analyse the root causes and show you where the output is going. There is no fee. What it asks of you is a named owner, read-only access and a few days of your engineering team's time.
See what the pilot asks of you →01
Subset of machines
Start with target assets on your floor
02
Live data capture
Existing read-only signals first
03
Proven ROI gain
Quantified evidence before any cost
04
Scale or stop
You keep the insights & decide
No machine left behind.
Modern PLCs, older machines, manual assembly benches, third-party sensors, spreadsheets, inspection processes, MES, ERP and the people who know where the awkward workarounds live. DataQI joins the production picture without asking you to replace the factory first.
Old and new machines
Use existing interfaces first. Read control signals where older equipment has no modern connection. Add sensing or vision only where the production question needs it.
Alongside MES and ERP
Your MES runs the factory. DataQI helps you learn from it. Production, maintenance and business information can be brought together without abandoning the systems people already use.
On your terms
On-premise and UK-hosted deployment are available. Your data never has to leave the building.
Discuss a production problem.
Bring one line, one cell or one manual process. Leave with a practical next step.
Discuss a production problem →