Your downtime report shows when the machine stopped and when it started again. It does not show the operator standing at the station waiting for Materials, Maintenance or Quality to walk over. That waiting is usually about half the number, and nothing on your floor times it today.
MMCall has built wireless on-site alert systems since 2009. Andon System 4.0 is the one for manufacturing.
A call at a station starts three ways: an operator presses a button, a machine raises it off a signal it already produces, or your own MES, SCADA or CMMS fires it through an API. However it starts, the right team gets it on a wrist pager within seconds, it climbs to the next person on its own if nobody answers, and the clock runs from the press to the arrival to the close.
Two days in you have your first ranked list: your longest waits and your busiest stations, off real shifts. It is never the list anyone would have guessed.
The core runs on its own radio mesh. No Wi-Fi, no internet, no PLC programming. IT is involved at exactly one point, installing the software on one Windows PC, and then never again. Nothing goes to a cloud. Buttons go up in under an hour with no wiring, and you brief your own shift in about five minutes.
Plants running it today include a Tier-1 automotive casting plant that cut maintenance response time 40% across 75 lines, a Fortune 100 distribution center covering 200 stations across 2.1 million square feet, and an FDA-regulated medical device manufacturer that cleared it through a formal corporate IT risk assessment.
You buy it once. No subscription and no per-user fees. Two-year warranty, and support and firmware updates for life.
US plants can run it on a real line free for 60 days first. We ship the hardware at no cost and it goes back free if you don't keep it.
It starts with a 30-minute call about your floor.