The Problem
Manufacturers Are Flying Blind,
Costing Millions
Modern factories are operating like black boxes—machines run, products ship, but critical operational insights remain invisible. This lack of visibility is silently draining profitability and competitiveness across the manufacturing sector.
FactoryMetrics: Manufacturing Intelligence from Planning to Dispatch
Delivery, quality, and consistency define your customers’ confidence in your factory. FactoryMetrics connects machine data, people, material, and production workflows so your teams can identify problems earlier and act using a shared operational record.
Protect delivery commitments
The problem: Downtime, shortages, and bottlenecks push production behind schedule.
Our solution: Simulate before you commit. Test capacity, material availability, and bottlenecks before promising a delivery date. When a breakdown, shortage, or delay occurs, automatically adjust schedules and priorities within approved rules—helping teams recover lost time and identify opportunities to deliver ahead of plan.
ModulesAdvanced planning & forecasting
Strengthen quality control
The problem: Missed checks and process deviations create rejection and rework.
Our solution: Anticipate quality risks before they become rework. Combine inspection results, part history, process data, and vision inputs with AI tailored to your shopfloor. Evaluate corrective actions before applying them, and trigger approved checks or process interlocks when deviations appear.
ModulesDigital route card · Part traceability · Batch genealogy · Digital documents · Sensor & gauge integration · Poka-yoke for critical operations and processes
Make performance consistent
The problem: Results vary across operators, shifts, machines, and batches.
Our solution: Turn shopfloor knowledge into repeatable decisions. Use customized, model-agnostic LLMs trained for your workflows, terminology, and operating needs. Compare shifts, machines, and batches, simulate improvements, and adapt approved workflows as conditions change—so teams can respond consistently to everyday disruptions.
ModulesOEE · Downtime · Reporting · Andon · Alerts · Notifications · Predictive maintenance · Quality
Where FactoryMetrics Fits in Your Factory
Connect business planning with shopfloor execution, quality, and traceability. FactoryMetrics brings operational data into one manufacturing intelligence platform and integrates with your existing systems.
| WHERE WE FIT | MODULES | FACTORYMETRICS (HIOTRON) | ERP | APS | CMMS | QMS | CBM | DIGITAL DOCS |
|---|---|---|---|---|---|---|---|---|
| Business Operations (ERP)Level 4 | 1. Sales Orders | ✓ | ||||||
| 2. Inventory Management | ✓ | |||||||
| 3. Long-Term Planning | ✓ | |||||||
| 4. Work Order Management | ✓ | |||||||
| Manufacturing Execution (MES)Level 3 | 5. Raw Material to Finished Goods Traceability | ✓ | ||||||
| 6. Digital Documents | ✓ | ✓ | ||||||
| 7. Production Planning & Scheduling | ✓ | ✓ | ||||||
| 8. Operation Execution | ✓ | ✓ | ||||||
| 9. Downtime & 4M Management | ✓ | ✓ | ||||||
| 10. Quality Management | ✓ | ✓ | ||||||
| 11. Preventive & Predictive Maintenance Management | ✓ | ✓ | ||||||
| 12. Condition-Based Monitoring (CBM) | ✓ | ✓ | ✓ | |||||
| Connectivity & ControlLevels 0, 1, 2 | 13. OEE & Analytics | ✓ | ||||||
| 14. Real-Time Data Collection | ✓ |
Illustrative coverage adapted from the supplied matrix. Adjacent systems can have overlapping capabilities. FactoryMetrics modules and integrations are configured to the requirements of each deployment.
Build the Foundation for a Dark Factory
Reduce manual data entry and repeated follow-ups. Connect machine data, standardize workflows, and automate configured checks and exception reporting. FactoryMetrics supports the digital foundation for greater automation, alongside the machinery and physical automation needed for lights-out operations.
- Live OEE Dashboard Track Availability, Performance, Quality in real-time with drill-down loss analysis
- Machine State Monitoring Color-coded status (Running/Idle/Stopped/Setup) with granular reason codes
- Cycle Time Analysis Compare actual vs. standard times with variance alerts (+/- 10% thresholds)
- Downtime Intelligence Machine-wise reason tagging (breakdowns, setups, material delays) + MTTR/MTBF trends.
- Andon Integration Auto-trigger visual/audio alerts for line stoppages with location mapping
- Job Progress Tracking Real-time completion % against schedule with bottleneck identification
- Spindle Health Monitoring Vibration, temperature, load trends for predictive tool maintenance
- Operator Efficiency Scores Individual performance metrics vs. shift benchmarks
- Energy-Per-Unit Calculation kW consumption correlated with production output
- Custom Report Builder Drag-and-drop KPIs for shift/daily/monthly views
- Smart Escalation Matrix Tiered notifications (Operator → Supervisor → Plant Head) with configurable timeouts
- Machine State Monitoring Color-coded status (Running/Idle/Stopped/Setup) with granular reason codes
- Cycle Time Analysis Compare actual vs. standard times with variance alerts (+/- 10% thresholds)
- Downtime Intelligence Machine-wise reason tagging (breakdowns, setups, material delays) + MTTR/MTBF trends.
- Andon Integration Auto-trigger visual/audio alerts for line stoppages with location mapping
- Job Progress Tracking Real-time completion % against schedule with bottleneck identification
- Spindle Health Monitoring Vibration, temperature, load trends for predictive tool maintenance
- Operator Efficiency Scores Individual performance metrics vs. shift benchmarks
- Energy-Per-Unit Calculation kW consumption correlated with production output
- Custom Report Builder Drag-and-drop KPIs for shift/daily/monthly views
Man
- Verifies attendance and skill levels of operators and line leaders using thumb scanners.
- Ensures the right personnel are at the right place with the right skills before operations commence.
Machines
- Monitors machine performance, breakdowns, alarms and alerts us to any issues or bottlenecks.
- Measures Overall Equipment Effectiveness (OEE), including availability, performance, and quality.
Methods
- Integrates and controls the assembly line operations.
- MeasuresRequires completion of specific checks before the line can be operated, ensuring adherence to our standard operating procedures.
Materials
- Confirms the availability of raw materials and child parts through barcode scanners.
- Tracks material utilization and inventory levels in real-time.
- Operational Integration and Control
- Condition-Based Monitoring Real-time data collection from sensors (vibration, temperature, current, and other critical parameters) for early fault detection.
- Machine Alarms & Automated Diagnosis Instant alarm notifications and auto-generated diagnostic reports via email and dashboard.
- Alarm Insights & Event Tracking Detailed logging of alarm occurrences, response times, and other open events for improved visibility.
- Sensor Clustering Logical grouping of sensors (e.g., Spindle Group: vibration + temperature + current) for better correlation of machine health data.
- Tool Life Tracking Count cycles/usage hours with replacement reminders
- AI-Powered Root Cause Analysis Historical event matching for accurate diagnosis of recurring failures.
- Self-Healing & Escalation Paths AI-driven recommendations with automated escalation workflows based on failure probability.
Intelligent Fault Detection
- Threshold-Based Triggers Configurable normal, warning, and critical limits.
- AI-Driven Fault Recommendations Smart insights for predictive failure analysis.
- Dynamic Thresholds Adaptive settings based on real-time operating conditions such warning, normal & critical.
Digital Documents Operator assistance module using touch screen tablet on machine
- Operators can access the view documents such as drawings, pdf, work instructions etc.
- Operators can fill the checklists like shift start, setup change, quality, JH, autonomous checklist.
- Operators can get training using images, video & other notifications, messages on screen.
Part Traceability & Machine interlocking – Trace part using single QR code & Interlock machines in case any process not followed & deviations such as
- If duplicate part found.
- Variant not match
- Sequence or process bypassed
- Quality not correct
- NG part not rejected
- rejection confirmation signal not high
- Scanning not done or correct
- Less cycle time
- Condition-Based Monitoring Real-time data collection from sensors (vibration, temperature, current, and other critical parameters) for early fault detection.
- Machine Alarms & Automated Diagnosis Instant alarm notifications and auto-generated diagnostic reports via email and dashboard.
- Alarm Insights & Event Tracking Detailed logging of alarm occurrences, response times, and other open events for improved visibility.
- Sensor Clustering Logical grouping of sensors (e.g., Spindle Group: vibration + temperature + current) for better correlation of machine health data.
- Tool Life Tracking Count cycles/usage hours with replacement reminders
- AI-Powered Root Cause Analysis Historical event matching for accurate diagnosis of recurring failures.
- Self-Healing & Escalation Paths AI-driven recommendations with automated escalation workflows based on failure probability.
Intelligent Fault Detection
- Threshold-Based Triggers Configurable normal, warning, and critical limits.
- AI-Driven Fault Recommendations Smart insights for predictive failure analysis.
- Dynamic Thresholds Adaptive settings based on real-time operating conditions such warning, normal & critical.
Production Planning & Scheduling
- Finite Capacity Scheduling Optimize sequences considering constraints
- Changeover Time Reduction AI-suggested product sequencing
- Material Readiness Verification Auto-check inventory before scheduling
- Dynamic Rescheduling Adjust for breakdowns/priority orders in real-time
- Shift Pattern Planning Align crew schedules with production peaks
Advance Quality Control System
- SPC Charting Real-time control charts (X-bar R, CpK) with zone rule violations.
- Rework InstructionsDigital work orders with highlighted defect areas.
- Cost of Poor Quality (COPQ) Scrap/rework cost allocation per product line.
- Customer Complaint Analytics Trend field failures back to production batches.
- Machine-Level kWh Tracking Identify energy hogs per shift/product
- Peak Demand Alerts Prevent utility penalty charges
- Idle Power Reports Quantify waste from non-production hours
- Inventory Lighting Automation Auto inventory tracking & activate light of specific SKU in case short or empty with notification to respective personal
- AI-Based Defect Classification Sort defects by type/severity
- Dimensional Gauging Camera-based micrometer measurements
- Barcode Verification Ensure correct labels/packaging
- Closed-Loop Correction Auto-adjust processes when defects exceed thresholds
From Installation to Insights in just 2 Hours
Unlike complex industrial platforms requiring months of deployment, FactoryMetrics delivers immediate value through our streamlined implementation process. We’ve eliminated the traditional barriers to Industry 4.0 adoption.
Connect
Analyse
Improve
Configurable. Flexible. Scalable.
Modular architecture for any setup, any scale, any complexity
Universal Machine
Connectivity
Connect effortlessly any machine, make or model. Whether automated, semi-automated, or manual, FactoryMetrics adapts to your factory floor and even supports custom protocol integration.
Seamless 3rd Party Software
Integration
Enrich Your
Data Lake
Connectivity
"The Foundation of Digital Transformation Success"
Seamlessly connected and extracted data from 45+ industry-leading and custom controllers, machines, PLCs, and protocols with Minimal (less than 30 mins) Downtime.
Integration
"Bridge the Gap Between Shop Floor & Top Floor"
From defining goals to automating data entry: we seamlessly integrate with 3rd-party software (ERP, HRMS, Planning), ensuring accurate, real-time data flow without the manual entry.
Do More With Your Data
Turn everyday operations into intelligent actions.
From the shop floor to the top floor, empower every department with real-time insights, predictive intelligence, and measurable outcomes.
Optimization / Manufacturing
Engineer efficiency.
- Discover hidden losses and cycle-time deviations
- Benchmark line performance with live data
- Validate process changes through real-time feedback
- Accelerate kaizen and digital transformation goals
Production Team
Deliver more, waste less.
- Monitor shift performance and production trends live
- Minimize downtime with automated alerts
- Ensure target adherence with visual dashboards
- Simplify reporting with accurate, auto-collected data
Operators / Supervisors
Empower people on the line
- Get guided alerts and digital work instructions
- Eliminate manual entries and guesswork
- Track job status, quality, and downtime in one screen
- Build accountability and ownership through visibility
Quality Team
Ensure precision with.
- Capture real-time quality data from machines and gauges
- Trace every defect back to its root cause instantly
- Link process data with inspection and test results
- Drive proactive quality control instead of reactive checks
Maintenance Team
Predict before it breaks.
- Monitor machine health and performance trends
- Get predictive maintenance alerts before failures
- Track MTTR, MTBF, and spare part usage automatically
- Reduce unplanned downtime and extend asset life
Why Choose Factormetrics: Powering Smart Factories
Real-Time Monitoring
OEE Boost
End to end part Traceability
Autonomous Operations
Paperless Workflows
Downtime Reduction
Seamless Integration
Energy Efficiency
Human Empowerment
Digital Compliance
Predictive Maintenance
Unified Insights
Real-Time Visibility
Centralise Monitoring
Process Optimization
Data Integrity
Quality Assurance
Production Transparency
Sustainable Manufacturing
Operational Excellence
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