The target keeps slipping.
The line looks busy, but it’s running below capacity. Micro-stoppages hide inside the normal sequence.
Continuous line optimization. Powered by edge AI.
How much are
hidden micro-stoppages
costing your plant?
LineLens analyzes your existing PLC data in real time to find hidden micro-stoppages, identify root causes, and rank bottlenecks by impact. Your maintenance team gets a clear focus in weeks, not months.
For automated discrete manufacturing. Analysis stays on-site.
What are lost minutes worth at your location?
ESTIMATOR0 min60 min
ESTIMATED ANNUAL DOWNTIME COST
Find out what’s happening on your line
8 min × $75 / min × 500 shifts × 1 site
Estimated downtime cost based on your assumptions, applied equally across the selected sites. This is not a savings forecast.
Reads the PLC data you already have
Edge AI. Data stays on-site.
Results in weeks
01 / THE HIDDEN LOSS
SECONDS ADD UP.You can’t recover
what you can’t see.
A fraction of a second at one station. A delay passed to the next. By the end of the shift, output is short, and your team is still trying to explain why.
Your experts are chasing symptoms.
Stopwatches and spot checks capture a moment. The cause may have started several steps upstream.
The bottleneck keeps moving.
You resolve one bottleneck. Another takes its place. Yesterday’s answer isn’t always today’s priority.
02 / A NEW WAY TO SEE YOUR LINE
FROM SPOT CHECKS TO CONTINUOUS INSIGHTYour team can’t be everywhere.
Now their insight can.
Like having a thousand line optimization engineers watching every step, all the time. LineLens brings real-time insights from edge AI to the PLC data already on your factory floor.
01 / A MOMENT IN TIME
A stopwatch sees a moment. Your line never stops changing.
A few experts observe a complex line. Between those observations, micro-stoppages can go unseen.
THE VISIBILITY GAPBetween spot checks
The delay may be over before anyone sees it.
Illustrative animation, not a product screen. The lighthouse observers represent analysis of available PLC step and state data. Your team decides and implements the fixes.
03 / SEE MORE. MAKE MORE POSSIBLE.
Your team.
A new superpower.
You have a limited maintenance team and only so many hours in the day. LineLens gives them a new superpower: a bullseye for where to focus, from the production line down to the exact step, ranked by impact.
- Put your best people on the highest-impact work.Use ranked bottlenecks to focus maintenance, controls, and process engineering on the biggest opportunities.
- Know exactly where to act.Which line. Which cell in that line. Which station. Which sequence. Which step. LineLens pinpoints the root cause so your team can spend less time searching and more time improving.
- Make every maintenance window count.As fixes land and priorities change, focus your available people and time on the work with the greatest potential return.
ROOT CAUSELocated.
BOTTLENECKSRanked.
STOPWATCH + CLIPBOARDPOWERED BY LINELENS
PRECISE LOCATION. CLEAR PRIORITY.
A bullseye for your team.
- Line
- Cell
- Station
- Sequence
- Step
Real-time insights pinpoint the root cause at the exact step. Bottlenecks ranked by impact show your team where its time can make the biggest difference.
04 / START WITH ONE LINE
Bring your
toughest line.
Let the numbers speak for themselves.
Start with a scoped pilot on one line and agree up front on what success looks like. If the ROI supports scaling, scale. The numbers decide. No guesswork.
- 01 / FOCUSChoose your line.
Agree on the output challenge, scope, and success criteria. Confirm PLC access and site approvals.
- 02 / OBSERVESee what’s happening.
Edge AI analyzes live sequences, detects micro-stoppages, and identifies the root causes of delays.
- 03 / DECIDEScale when the ROI says so.
Review the findings and financial case against your success criteria. Expand to more lines and sites only when the numbers say so.
Built for sequenced, PLC-controlled production.
Automotive & suppliers · Food & beverage · Heavy equipment · Appliances · Packaging
Let’s start with your operation.
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A FEW PRACTICAL QUESTIONS
Before we
get started.
Does LineLens automatically change the line?
LineLens automates detection, analysis, and improvement prioritization. Your team decides and implements process changes. Read-only PLC access means LineLens does not write control commands. After a fix, it continues monitoring and updates the bottlenecks ranked by impact.
What kind of production line is a good fit?
High-volume, sequenced lines with multiple cells, robots, or stations, where PLCs report step or state changes. A strong fit is a line running below rated capacity, with a meaningful cost for lost production time.
Does our production data leave the plant?
Your production data stays in your plant, under your site’s security controls, and remains yours. Edge AI analyzes it in real time inside your private network. Air-gapped operation keeps analysis disconnected from the internet, reducing external exposure. LineLens uses read-only PLC access and never writes control commands.
Will LineLens change how our PLCs run?
LineLens uses read-only PLC access to observe step and state changes. It does not write control commands to the PLC.
Do we need a data-science team?
No. LineLens automates the analysis, reducing manual investigation and custom data modeling. Your controls and operations teams supply process knowledge and help define the evaluation goals.
What will we evaluate in the pilot?
The scoped pilot focuses on one line: ranking its bottlenecks by impact, seeing late steps, identifying the root causes of delays, and estimating lost time and financial impact. Agree on scope, duration, and success criteria up front. Use the pilot’s results and potential ROI to decide whether to scale.