Ikshana connects to shop-floor PLCs in real time to isolate downtime, overcycles, and equipment faults across your entire production line. By decoupling genuine machine breakdowns from upstream blocking and downstream starvation, Ikshana reveals the root causes behind every performance loss—showing teams exactly how to recover line throughput.
Optimizing machines in isolation rarely increases line throughput. Meaningful production gains come from data-driven manufacturing analytics that model how interconnected stations, dynamic buffers, and machine events interact based on live datapoints.
| Evaluation Area |
Conventional Approach
Isolated Asset Monitoring & Generic Copilots
|
Linecraft Ikshana Platform
Data-Driven Line Flow Analytics
|
|---|---|---|
| Operational Scope System vs Asset Modeling |
Machine Silos
Calculates isolated OEE per asset without line flow context, ignoring how upstream and downstream stations interact. |
Interconnected Line Modeling
Recreates continuous line flow, dynamic buffer capacities, and transfer intervals directly from sub-second PLC datapoints. |
| Bottleneck Detection Constraint Tracking |
Buffer-Blind & Static
Confuses genuine machine breakdown with line starvation and downstream blocking. Assumes static bottleneck locations. |
Transient Bottleneck Detection
Catches shifting dynamic constraints in real time as buffer levels rise and fall across serial and parallel conveyor networks. |
| Loss Attribution Root-Cause Tracing |
Alert Fatigue
Triggers hundreds of noisy micro-alarms per shift that have zero measurable correlation to finished line throughput. |
Root-Cause Decoupling
Traces throughput loss to exact machine states and timestamps, decoupling true downtime from conveyor-induced idle time. |
| Engineering ROI Capacity & CapEx Guidance |
Misdirected CapEx
Spends engineering hours or capital speeding up non-critical stations without producing a single additional finished part. |
Demonstrated Flow Potential
Unlocks proven, unrecovered machine capacity and directs engineering fixes strictly to pacing constraints with $0 CapEx. |
Explore the purpose-built modules powering Ikshana's data-driven manufacturing analytics and bottleneck intelligence engine.
A modern production line is an interconnected ecosystem of machines, dynamic accumulators, and transfer gantries. When one machine stumbles, the ripple effect blocks upstream stations and starves downstream bays. Ikshana monitors the continuous line flow based on granular PLC datapoints to isolate the true pacing constraint.
OP20 is lagging behind takt by 8 seconds per part. Because manufacturing is an interconnected flow, Buffer 1 quickly saturates to 100%, forcing OP10 into Blocked status. Simultaneously, Buffer 2 completely empties, forcing OP30 into Starved status. Both OP10 and OP30 are 100% healthy, yet neither can produce parts.
Ikshana connects directly to native PLC registers and conveyor sensors at sub-second intervals. It reconstructs the continuous line pulse without modifying PLC ladder logic.
Separates mechanical stoppage from buffer starvation and transfer gantry delays.
Alerts when constraints migrate across stations due to variant mix changes or operator rotations.
Simulates accumulator sizing to prevent micro-stops from propagating across cells.
52s cycle time vs 44s takt pace. Creating 14.2s blockage on Cell 01.
Downstream weld station starved of WIP for 18 minutes this shift.
Demonstrated Flow Potential proves 16 JPH recoverable capacity.
View your line metrics and KPIs in a single glance. Customize views for operators, plant managers and executives, so everyone sees the data that matters most to them.
Go beyond a simple up/down status. Monitor key physical parameters — like temperature, pressure and clamp times — for every cell on your line, polled at sub-second intervals.
See whether your line is meeting targets and monitor shift-level pacing in real time. Compare output across shifts, days and historical benchmarks.
Automatically find which machines are the real constraint on your line. Stop spending money optimizing the wrong stations — let Ikshana's algorithm identify the actual flow restrictor.
Drill down into the specific assets that need closer monitoring, based on historical criticality. Set up SMS and email alerts for specific micro-fault conditions.
Stop guessing why you missed shift targets. Ikshana automatically captures and categorizes every micro-stoppage, so you can analyze each loss and its root cause instantly.
Trace the exact lifecycle of a specific part through the entire production line, including every quality parameter and environmental condition at the moment it was processed.
Get notified the moment a machine deviates from its normal range — before a micro-fault turns into unplanned downtime. Set thresholds per machine, per shift, or per line.
Create and schedule reports using out-of-the-box templates, or build your own — so plant managers and executives get the numbers they need without asking someone to pull a spreadsheet.
Map your raw PLC tags to standardized data definitions in minutes, using a visual interface — no custom ladder logic or edge code required.
A five-phase engineering process that turns raw PLC telemetry into actionable throughput gains.
An industrial edge appliance connects non-invasively to your machine PLCs, mapping line topology, buffer capacities, and tag registers without modifying PLC code.
Captures sub-second machine states, mechanical cycle durations, and buffer fill levels via secure industrial protocols to your on-premise server or private cloud.
Our discrete-event engine models dynamic flow and buffer levels across all assets directly from actual shopfloor data, separating genuine station downtime from upstream starvation and downstream blocking.
Identifies shifting constraints in real time, computes their exact throughput loss, and traces each loss back to root machine events.
Gives continuous improvement teams prioritized actions showing exactly where cycle time reductions or reliability fixes produce the greatest line output gain.