Built for the Production Floor
Six modules. Each one targeting a specific operational blind spot. All feeding into one dashboard.
OpsPulse
Real-Time Throughput MonitorThe Problem
Operations managers find out throughput dropped at end of shift — 7 hours after they could have acted on it.
OpsPulse monitors throughput continuously on 15-minute rolling intervals and fires alerts when performance deviates from target.
What It Tracks
- Units per hour (UPH) at line, zone, and facility level
- OEE (Overall Equipment Effectiveness) — calculated automatically
- Throughput rate variance vs. target
- First-pass yield rate
- Shift-over-shift trend with statistical variance
- Week-over-week throughput comparison
The Dashboard Shows
- →Live UPH gauge with color-coded deviation (green/amber/red)
- →OEE breakdown — Availability, Performance, Quality components
- →Hourly throughput heatmap for the shift
- →Alert log with timestamps and auto-resolved status
- →Shift summary report auto-generated at end of shift
FlowAI
AI-Powered Bottleneck IntelligenceThe Problem
Bottlenecks are identified by supervisors walking the floor and telling the manager. That's a slow, incomplete, and inconsistent signal.
FlowAI maps your production flow in real time, identifies where throughput is constrained, quantifies the revenue impact, and recommends corrective actions.
What It Tracks
- Cycle time at each station/zone vs. takt time
- Queue depth and wait time between operations
- Constraint propagation — upstream and downstream effects
- Bottleneck duration and frequency
- Revenue impact of identified constraints
The Dashboard Shows
- →Flow map visualization with constraint highlighted in real time
- →Impact calculator — "this bottleneck is costing $X/hour"
- →AI recommendation panel — what to do right now
- →Constraint history log — recurring bottlenecks identified
- →Theory of Constraints analysis for the facility
WasteWatch
Real-Time Waste & Scrap TrackingThe Problem
Waste shows up as a cost in the P&L but nobody knows where it's happening, on which shift, in which zone, or from which root cause.
WasteWatch tracks waste and scrap in real time, categorized by the 8 Lean wastes, with zone-level attribution and automatic cost calculation.
What It Tracks
- Scrap rate by zone, shift, and SKU
- Waste categorized by Lean waste type (DOWNTIME)
- Rework volume and rework cost
- Startup rejection rate after changeovers
- Waste trend — daily, weekly, monthly
- Cost of waste in real dollars based on material cost
The Dashboard Shows
- →Waste rate gauge — live % of total output
- →Pareto chart — top 3 waste sources this shift
- →Zone-level waste heat map
- →Lean waste category breakdown (pie chart)
- →Monthly waste cost report vs. target
ShiftAdvisor
Headcount & Shift OptimizationThe Problem
Labor is 50–70% of warehouse cost. Managers often don't know which zones are over-staffed and which are causing throughput to choke due to under-staffing.
ShiftAdvisor analyzes throughput-per-person by zone and shift, identifies misallocated headcount, and recommends real-time adjustments.
What It Tracks
- Labor cost per unit (LCPU) — the efficiency metric
- Throughput per person by zone and shift
- Headcount utilization rate — active vs. idle time
- Overtime hours vs. output
- Shift-over-shift labor efficiency comparison
- Absenteeism impact on throughput
The Dashboard Shows
- →Headcount allocation map — who is where, what's the output
- →Zone efficiency scores — green/amber/red
- →Labor cost per unit trend with target line
- →Shift comparison matrix — A vs. B vs. C shift efficiency
- →Daily labor utilization report
Ask OpsOS
AI Operations AnalystThe Problem
Answering "why did throughput drop Tuesday night?" requires pulling reports, cross-referencing downtime logs, and manually connecting dots — a 2-hour process.
Ask OpsOS is a natural language AI that answers operations questions with data, root-cause analysis, and recommended actions in under 60 seconds.
What It Tracks
- All operational data across all active modules
- Historical patterns and anomalies
- Shift-specific events and their effects on performance
- Correlation between operational variables
The Dashboard Shows
- →Chat interface — ask in plain English, get data-backed answers
- →Auto-generated daily briefing delivered at shift start
- →Root-cause analysis report on any deviation
- →Week-in-review summary every Monday morning
- →Exportable reports for leadership presentations
SafetyShield
Safety Incident IntelligenceThe Problem
Safety data lives in paper logs, OSHA forms, and email chains. TRIR is calculated at year-end. Near-misses go untracked. Patterns are invisible.
SafetyShield tracks incidents, near-misses, and safety observations in real time with automatic TRIR calculation and OEM-ready reporting.
What It Tracks
- Recordable incidents with OSHA classification
- Near-miss events with location and condition
- Safety observations submitted by floor employees
- TRIR — calculated automatically, updated in real time
- Corrective action completion rate
- Safety event correlation with operational conditions
The Dashboard Shows
- →TRIR gauge — live, updated with every new incident
- →Incident map — where on the floor are events happening
- →Near-miss log with corrective action tracking
- →OEM-ready safety report (downloadable PDF)
- →Safety trend — 30/60/90 day rolling window
Lean Toolkit
Included with every OpsOS subscription: a library of Lean operations tools — value stream mapping templates, 5S audit checklists, A3 problem-solving forms, Kaizen event templates, and OEE improvement worksheets. All downloadable, all formatted for manufacturing operations.
Included in all plansSee OpsOS on Your Operation
30-minute live demo. We connect to your data. You see your actual throughput, bottlenecks, and waste — not a generic slideshow.