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Night shift · Line 3 · an illustrative scenario
Right now, a machine on your floor is telling you something.
Nobody is listening yet. This is the three-minute story of what changes when you can hear it.
Plant clock
02:14:07
Line 3 · down for
00:41:12
Cause: unknown. First report: a WhatsApp photo.
Scroll · keep the clock in mind
Act 1 · The cost of not knowing
Downtime is not the expensive part. Not knowing is.
You find out from the night shift
The machine knew 40 minutes before anyone did. Vibration drifted, temperature crept, cycle time stretched. None of it reached a person until it was a stoppage.
The batch record exists. In a binder.
Three buildings away, in handwriting, with a signature from a shift that ended at six. Audit week is a fortnight of searching for paper you already have.
The defect you ship is found by the customer
Then the trace begins: which lot, which shift, which parameter. Without unit-level genealogy you recall the lot. All of it.
Your number, not ours
What did those 41 minutes cost?
Tonight
82,000
A year of nights like it
98,07,200
Assumes ~2.3 unplanned stops a week, which is conservative for a mixed line. The point is not the exact figure. It is that the figure was knowable 40 minutes earlier.
Act 2 · What if the floor could talk back?
Sheet 01 · Production overview
The whole plant, in one glance
Orders in progress, inspection pass rate, work-centre activity and everything that needs a decision: overdue orders, open non-conformances, maintenance plans. The morning meeting starts with facts, not photos of HMI screens.
01 / 06
efm · live
Act 2½ · Agents that do the work
Two colleagues who never sleep, and never guess.
EFM ships AI agents that read the same MES records your engineers do. One explains downtime with evidence. One re-plans the shift when reality changes. Both show their working, and both wait for a human before anything moves.
Downtime root-cause analysis · replay of a real run
efm.agent.downtime-rca@0.2.0 · run 7e18c85b
Advisory AI analysis checked against MES evidence. A qualified engineer reviews it before any action.
Resource scheduling · live re-plan
efm.agent.planner· shift 06:00–14:00 · Dubai Plastics
06:0008:0010:0012:0014:00
Mixer WOD
WO-26105 · CLM20
WO-26106 · CLM20
WO-26107 · CLM20
Mixer 2
WO-26110 · PET-1L
WO-26111 · PET-1L
Press 01
WO-26118 · CAP38
CNC 02
WO-26119 · TL-BTL
Shift plan as released. Seven orders across four work centres, takt on target.
Agents propose; people approve. Every proposal carries its evidence and lands in the Action Center with an audit trail.
Act 3 · The same night, with EFM
At 02:16, the work order already existed.
Same machine, same bearing. The only difference is who heard it first.
02:14:07
Bearing vibration on Press 01 crosses its learned baseline. The edge model scores it 0.81.
02:14:09
EFM raises a predictive-maintenance alert and a work order on the edge node. No cloud involved.
02:14:30
The twin re-sequences 42 parts to the CNC buffer. Takt is protected at −4%.
02:16:00
Maintenance is paged with the part number. The bearing swap is booked for the planned window.
06:00:00
Day shift reads the whole thing in the morning report. Nobody searched for a binder.
Act 4 · What changes in 90 days
Platform benchmarks across live EFM sites
Faster operator training
Less scrap & rework
OEE & throughput uplift
Unit-level traceability
What you are probably thinking
“We can’t stop production to install anything.”
You don’t. EFM runs beside what you have, reads what the PLCs already say, and starts with one line. A pilot takes two weeks.
“Our connectivity is unreliable.”
That is the premise. Execution, models and records live on an edge node in the plant. When the internet drops, the line does not notice.
“Our data can’t leave the plant.”
It doesn’t have to. The edge node is the system of record. What syncs upward is your choice, field by field.
“We run SAP.”
So do most of our customers. Native bridges for MII, ME and Digital Manufacturing keep SAP as the ERP truth while execution moves to the edge.
Your line, next
Bring one problem line. We’ll show you what it has been saying.
A 30-minute walkthrough on your process, not a slide deck. If it is a fit, one cell runs on an EFM edge node within two weeks.