Reason codes captured automatically at ~100% accuracy. OEE broken down live by Availability, Performance, Quality — across every shift, line, and plant. The Six Big Losses on one screen. TPM the way the book intended.
The one number your TPM program lives by, computed continuously from your plant data — not entered on Excel next morning.
TPM's canonical loss framework. EdgeBits captures each one at source, categorises automatically, and rolls up into your Top Loss report by shift, line, or plant.
Tooling failure, motor failure, PLC alarm — anything that halts production unexpectedly.
Predictive alerts on motor current, bearing temperature, vibration drift. Operator gets an SMS 30 minutes before the failure, not 30 minutes after.
Changeovers, material shortages, warm-up time delaying production start.
Changeover timer starts and stops automatically from tag events. Setup-time trend by operator, shift, and product. Focused Improvement teams get the data they need.
Brief interruptions under 5 minutes — the ones your SCADA misses and your operators fix without logging.
Sub-second sampling catches every stop, no matter how short. Reason codes suggested from the audit chain — operator confirms in one tap.
Equipment running below theoretical speed. Wear, misalignment, sensor drift.
Live cycle-time vs Ideal Cycle Time by asset. Drift detected the moment it starts, not on the monthly review.
Scrap and rework during steady-state production.
SPC alerts on CTQ variables (temperature, fill weight, coating thickness). Catch drift at 30 minutes, not at 4 hours when the shift is already scrap.
Rejects during startup or early production phases.
Startup-yield trend per product per line. Compare shifts. The operator who consistently gets clean startups shows up on the dashboard.
The single most quoted TPM stat. Every loss you can't attribute is a loss you can't fix — and a Top Loss report you can't trust.
EdgeBits stamps every stop with the causal chain: which sensor flipped first, which alarm fired, which operator overrode, which config changed. The audit chain proposes the reason; the operator confirms in one tap.
We don't replace TPM. We give it the data it always needed. Here's where we plug in — and where you keep leading the program.
Operator dashboard shows exactly which of their tags are drifting. Ask the assistant "any lubrication due on line 3?" in plain English.
EdgeBits acceleratesComponent Log auto-populated from real sensor runtime. No more "we think this bearing has ~2000 hours" — you know exactly.
EdgeBits acceleratesCTQ variables monitored live with SPC bands. Root Cause Analysis fed by the audit chain — what changed, when, and by whom.
EdgeBits acceleratesCross-plant, cross-shift comparison in seconds. Kaizen teams stop arguing about numbers and start proposing fixes.
EdgeBits acceleratesEvery setpoint change, every config edit, every operator override stamped. Pass the audit chain to your OEM as design feedback.
EdgeBits acceleratesYour program. We give your trainer the incident replay data to build case studies from real events.
You lead · we supportYour program. Interlock and alarm data are visible on our audit chain if you want them in the same view.
You lead · we supportOut of scope for now. When you're ready to instrument administrative flows we'll talk.
Out of scopeThe assistant speaks OEE. It speaks Six Big Losses. It speaks Top Loss reports and Component Logs. Your TPM manager asks a question the way they'd ask it in a Kaizen review, and gets the answer with the audit trail attached.
Every answer cites the specific sensor readings, audit-chain events, and time windows so the reasoning trail is verifiable.
How the assistant works30-minute call. Bring your OEE numbers. We'll show you where EdgeBits shrinks each of the Six Big Losses on your plant, live.