Built Exclusively for Manufacturing

Stop Guessing Why Your Lines Are Down. Start Knowing.

Ai.Downtime goes straight to the source — your equipment — to capture sub-second fault data, identify root causes, and give your team the clearest path from downtime event to resolution. No operator input. No guesswork. No gray areas.

Request a Demo → See How It Works

Live Production Monitor

Live

OEE

87.3%

Availability

91.2%

Top Loss

L3-Seal

Filler Head #3 — Seal Failure

Line 3 · 14 min ago · Root cause identified

Critical

Labeler Sync Drift — 2.4mm

Line 1 · Trending · Predictive alert

Watch

Case Packer Jam Cleared

Line 2 · 1h ago · Auto-resolved

Resolved

Built for production & packaging operations

Food & BeverageCPGAutomotiveIndustrial GoodsPackaging

The Problem

Most Downtime Systems Create Visibility. Not Answers.

Dropdown menus, operator logs, and spreadsheet trackers create the illusion of downtime management. But they rely on opinions, delayed reporting, and incomplete data — leaving your team chasing symptoms instead of causes.

🎯

Operator-Dependent Data

Operators code downtime from memory at the end of a shift. By then the details are gone, the context is lost, and the data is wrong.

🔗

Cascading Faults Look Like Root Causes

When Machine A faults and causes Machine B to stop, most systems blame Machine B. Your team fixes the wrong thing, and the problem comes right back.

📊

Activity Without Accountability

Reports get generated. Meetings get held. But without machine-level root cause data, decisions are based on opinions — not evidence.

Average Unplanned Downtime Cost

per hour of stopped production

Lost throughput$12,500/hr

Scrap & rework$3,200/hr

Labor waste$2,800/hr

Emergency response$1,500/hr

The Ai.Downtime Difference

From Opinions to Evidence. From Guesswork to Precision.

Traditional Downtime Tracking

✕Relies on operator input and dropdown menus

✕Data entered hours or shifts after events

✕Can't distinguish initiating fault from cascading faults

✕Spreadsheet-based analysis and manual reporting

✕Reactive — problems found only after major losses

✕Fixes aren't tracked or verified for effectiveness

Ai.Downtime

→Captures fault data directly from equipment — no operator input

→Sub-second fault timing with precise machine-level detail

→AI identifies the initiating root cause in complex fault chains

→Automated reports and real-time role-specific dashboards

→Predictive AI flags failures before they impact output

→Continuous improvement loop tracks and verifies every fix

The Methodology

A Structured Path From Downtime Data to Lasting Gains

Not just software — a proven, built-in approach that turns every fault event into a step toward operational excellence.

📡

Track

Automatically capture downtime and fault events with precise machine-level detail. No operator input required.

🔍

Analyze

AI-driven tools detect patterns, identify cascading faults, and uncover true root causes behind the symptoms.

🧩

Troubleshoot

Contextual insights and fault timelines help your team zero in on the real issue — not the most visible one.

🔧

Repair

Targeted fixes guided by clear data. bOpus delivers step-by-step guides right to your team's hands.

⚙️

Calibrate

Restore machines to correct operating parameters — centerlined and tuned for peak performance.

🚀

Optimize

Go beyond repair. Use historical trends to push equipment past its originally commissioned performance level.

The Platform

Everything Your Team Needs to Own Uptime

From real-time diagnostics to predictive intelligence, Ai.Downtime gives every role in your operation the insight to act — immediately.

⚡

AI-Driven Root Cause in Minutes

Sub-second fault timing identifies the initiating fault in complex chains. Your team always knows where to start — no more chasing symptoms down the line.

🔮

Predict Failures Before They Happen

Machine learning identifies patterns before breakdowns occur, shifting your operation from reactive firefighting to planned, preventive maintenance.

📊

Real-Time OEE Dashboards

Role-specific views for operators, supervisors, and plant managers. Top losses, trends, root causes, and gains — visualized so decisions happen immediately.

📋

Automated Reporting

Eliminate spreadsheet work with scheduled reports that tell the full story. More time fixing problems, less time documenting them.

🔄

Continuous Improvement Loop

Every fix feeds back into the system. Track corrective actions, verify effectiveness, and sustain gains. Your team gets smarter every time a problem is solved.

⏱️

Reduce Changeover Downtime

AI-powered event notifications and insights help teams make faster adjustments and get lines back up sooner between product runs.

Operator inputs required
for data collection

Sub-second fault
capture precision

Fault events auto-captured
from equipment

0/7

Cloud-accessible from
anywhere, any device

Included With Every Deployment

Ai.Downtime Finds the Problem. bOpus Helps Your Team Fix It.

Every Ai.Downtime customer gets bOpus — the knowledge platform that puts step-by-step troubleshooting guides, SOPs, and rich-media walkthroughs directly in your operators' and technicians' hands, right where work happens.

📱

Capture Know-How From the Floor

Frontline workers document real-world fixes from their phone — photos, video, spoken steps — in seconds, without disrupting work.

🔍

AI-Assisted Search & QR Access

The right guide surfaces instantly through AI search or QR codes placed directly on machines, tools, and workspaces.

🧠

Preserve Institutional Knowledge

Stop losing critical expertise when people leave, change roles, or retire. Your best performers' know-how stays with the company forever.

⚡

Faster Resolution, Every Time

New hires and experienced techs alike get the same step-by-step guidance — reducing mean time to repair across the board.

Industries

Built for Production. Proven Across Verticals.

Any production or packaging operation where uptime drives margins and predictability matters.

🍔

Food & Beverage

High-speed lines, strict compliance, zero tolerance for unplanned stops.

🧴

CPG

Multi-SKU changeovers, tight margins, demand for maximum OEE.

🚗

Automotive

Complex assembly, JIT schedules, cascading fault chains across cells.

🏭

Industrial Goods

Heavy equipment, long cycle times, predictive maintenance critical.

📦

Packaging

High-volume throughput, tight tolerances, changeover optimization.

Seamless Integration

Works With What You Have. No Rip-and-Replace.

Ai.Downtime connects to your existing infrastructure — from the machine level up. Secure cloud platform with full encryption, globally accessible, and no local IT burden.

Preferred — Direct to Equipment

🔌

PLCs & Controllers

Direct connection to programmable logic controllers for real-time fault and state data at the machine level.

Sub-second

📡

Sensors & I/O

Analog and digital signals captured directly — temperature, pressure, vibration, position, and more.

Sub-second

⚡

Most systems rely on operator input or higher-level software. Ai.Downtime goes straight to the equipment for sub-second fault data — the fastest, most accurate source of truth.

Also Supported — System Connections

💾

Historians

Connect to your existing data historians for trend and batch data.

System cycle time

🖥️

MES Systems

Integrate with manufacturing execution systems for production context.

System cycle time

📺

HMI & SCADA

Pull data from supervisory systems and operator interfaces.

System cycle time

Contextual Data

☁️

Cloud & Enterprise Systems

Pull in shift schedules, quality metrics, work orders, and more to enrich your downtime analysis with operational context.

Enrichment data

We stopped arguing about what was causing downtime. The system showed us. Within two weeks we'd eliminated our number one loss — and the fix was something we'd walked past for months.

— Plant Manager, Food & Beverage

Get Started

Ready to See Exactly Where Your Lines Are Losing Money — and How to Stop It?

Request a demo and see how Ai.Downtime identifies, fixes, and eliminates downtime across your production and packaging operations — with bOpus built right in.

Request a Demo → Download the Product Brief