Output is counted on paper
Production numbers arrive a day late, hand-written, and rounded.
Shopfloor Insight & Monitoring Kit
Your machines already know. Now you will too.
A plug-in IoT kit plus a web platform. Mount it on the machine, and production runs, stoppages, energy and OEE start recording themselves.
- No PLC integration
- No data entry
- Works on old machines
Extruder #3 — Shift A
6h 19mRunning
1h 14mDowntime
5Stoppages
18,420Units (meter)
The shift timeline — green is running, red is stopped. Tap a red block and say why.
Deployed and running
- Companies
- Machines
- People
running on SIM-Kit
monitored on the platform
on the shop floor and in the office
The problem
Most shopfloors run blind.
The machine already knows everything. Nobody is listening to it.
Downtime has no name
Everyone knows the machine stopped. Nobody knows how long, how often, or why — so the same failure repeats every month.
OEE is a slide, not a number
It's calculated once a quarter from memory, if at all.
Energy is one monthly bill
No idea which machine, which shift, or which hour ate it.
MES and SCADA quotes cost more than the machines they watch, and take months of integration. SIM-Kit measures the plant instead of running it.
What it is
Two halves that ship together.
The Kit
A compact IoT device that mounts at the machine and reads its electrical and production signals directly. No PLC integration project. No machine-vendor cooperation required. It reports over cellular — SIM card optionally supplied — or Wi-Fi.
The Platform
A responsive web app — mobile-first for the shop floor, full-depth on desktop — where supervisors run the shift and managers read the numbers. Every date, time and shift boundary is computed in IST.
What the device measures — every 5 seconds
Electrical
- 3-phase voltage — R, Y, B
- 3-phase current — R, Y, B
- 3-phase power factor
- Instantaneous power (kW)
- Cumulative energy (kWh)
Production
- Cumulative production count
- Instantaneous production speed
Condition
- Temperature
- Vibration
- Machine fault alarms
How it works
Four steps. One afternoon.
- 1
Mount the kit
The device clamps onto the machine's electrical and production signals. No PLC project, no machine-vendor sign-off.
- 2
It starts talking
Readings stream to the platform over cellular or Wi-Fi, on an encrypted, certificate-authenticated connection.
- 3
Runs and stops name themselves
Speed thresholds turn raw telemetry into green and red zones on the shift timeline. Your team only adds the "why."
- 4
The numbers arrive
OEE, energy cost, production, downtime Pareto and maintenance adherence — live, per machine, per shift, per date range.
Features
Everything below is shipping today.
No roadmap items. No asterisks.
Nobody presses "start."
The machine tells us when it's running.
The platform watches production speed off the device and opens a run the moment speed holds above your on-threshold for a sustained window — and closes it when speed drops to the off-threshold and stays there. Two thresholds and two dwell timers mean a brief dip mid-cycle doesn't fake a stoppage, and a stray pulse doesn't fake a run.
- Speed-on / speed-off thresholds, independently configurable
- "Sustained for N seconds" windows on both edges
- Checked every 15 seconds, around the clock
- Output from the physical meter, not a human estimate
For machines without a device — or when you prefer human control — manual start/stop with work order, produced and rejected quantity. Both modes live in the same timeline.
Speed (units/min) Run open
on-threshold off-threshold
The dip at mid-cycle stays inside the dwell window — no fake stoppage.
Name the stop once. Rank it forever.
Classic 80/20, computed for you.
Define stop-reason categories per machine — flagging which count as breakdowns — then the reasons under them. Every red zone gets classified, and the downtime report ranks them automatically: total minutes, occurrence count, average duration, share of total downtime, and running cumulative percentage.
- MTBF — mean time between failures
- MTTR — mean time to repair
- Category rollups, breakdown flag per category
Downtime Pareto — July
MTBF 6h 12m MTTR 11.3m
- 1 Die change412m ×26 31.2%
- 2 Material feed jam BD268m ×41 51.5%
- 3 No operator191m ×12 66.0%
- 4 Sensor fault BD154m ×19 77.7%
- 5 Power trip BD121m ×8 86.9%
- 6 Tool break BD96m ×11 94.2%
Cumulative % — the top two reasons account for 51.5% of all downtime.
Maintenance that schedules itself and grades itself.
Build a task template once per machine, then stop thinking about it.
- Three ways to schedule — every N weeks (optionally pinned to a weekday), after N running hours, or after N units produced. Hours and quantity are read from the machine's own activity, not a calendar guess.
- Rich instructions — formatted text with inline photos, so the person doing the job at 2am sees exactly what to touch.
- Tasks appear on their own — the schedule is checked several times a day and due tasks are raised automatically. Nothing is ever raised twice.
- Adherence scoring — on completion the system captures the actual value and grades it: 90–100% excellent, 70–89% good, below 70% poor.
Gearbox oil change
Due at250.0 h
Done at265.2 h
Adherence94%
Belt tension checkWeekly · Mon
Die plate cleanEvery 50,000 units
Filter replacementOverdue · 12 h
Machine faults, in plain English.
Name each alarm once. Read it forever.
Machines report faults as codes. Each one is named and graded once during setup, and from then on every machine card shows a readable alarm — "Phase R over-current", not a number nobody can look up. Anything the machine reports that hasn't been named yet is still shown, never silently dropped.
- Three severity levels, so a warning never reads like a breakdown
- The highest active severity is shown on the machine card
- Full fault history per machine
- Connectivity is reported honestly — when the platform can't reach a machine it says so, rather than inventing a status
Injection Moulder #7
Active faults 3
- Phase R over-current Breakdown
- Panel temperature high Warning
- Unnamed fault · code 21 Unknown
Highest active severity: Breakdown · saved to fault history
Update every device without leaving the office.
Pick the machines, press update, watch it land.
- Offline machines queue automatically and update on reconnect
- Live progress per machine, so you know what actually landed
- Cancel and retry any update; one at a time per machine
- A machine already on that version is skipped — no pointless downloads
- Every update is integrity-checked before it is applied
Tune the machine from the browser
Read a device's live settings and change them without opening the panel — production calibration, speed thresholds, temperature and current limits, rated power, dry-run threshold and network settings.
Device update v2.4.1
- Extruder #3 Updated
100%
- Injection Moulder #7 Updating
62%
- Press Line B Starting
8%
- Winder #2 Queued
offline — updates on reconnect
Reports
Five reports. One date range. Zero spreadsheets.
Every headline metric carries a popover with the exact formula and what each variable means. Argue with the number, not with the tool.
Availability
Availability
Availability = actual runtime ÷ planned time
- actual runtime
- — minutes the machine was in a production run
- planned time
- — configured shift window on active working days
84.2%
379 min ÷ 450 min
Performance
Performance
Performance = actual output ÷ ideal output
- actual output
- — units counted by the production meter
- ideal output
- — runtime ÷ the work order's ideal cycle time
91.6%
18,420 ÷ 20,110 units
Quality
Quality
Quality = good units ÷ total units
- good units
- — total units minus rejected units
- total units
- — everything the meter counted in the run
98.4%
18,125 good ÷ 18,420
OEE
OEE
OEE = Availability × Performance × Quality
- Availability
- — runtime against planned time
- Performance
- — output against ideal output
- Quality
- — good units against total units
75.9%
84.2% × 91.6% × 98.4%
Tap the on any card — that popover is the real one from the product.
OEE
Availability × Performance × Quality against your configured shift window and active working days. By shift, day, week or hour.
- Unit counts come from the production meter
- Reconciles with the production report
Energy & Cost
Total kWh, average / peak / minimum power, average 3-phase power factor, and cost from your rate — or a full time-of-day rate table.
- Peak vs off-peak split
- Specific Energy Consumption (kWh/unit)
Production
Total units, average speed, peak speed and minimum non-zero running speed, bucketed over time.
- Idle buckets excluded from the average
Downtime Pareto
Ranked stop reasons with cumulative percentage and category rollups. Optionally limited to the top N.
- MTBF and MTTR
- Average duration per occurrence
Maintenance
Total, completed, overdue and skipped tasks, completion rate, and average adherence percentage.
- Per-task expected vs actual
- Repeated-failure detection
Power draw — Shift A
Peak tariff Off-peak
06:0008:0010:0012:0014:00
- Total energy
- 312.4 kWh
- Peak power
- 47.2 kW
- Avg power factor
- 0.94
- Cost
- ₹2,743
- SEC
- 0.017 kWh/unit
What you'll see
Every number here is computed by the product.
Not a wish list — this is the metric surface you get on day one.
Effectiveness
- OEE %
- Availability %
- Performance %
- Quality %
Output
- Total units
- Average speed
- Peak speed
- Min running speed
Energy
- Total kWh
- Total cost ₹
- Peak power kW
- Avg power factor
- kWh per unit
- Peak vs off-peak
Downtime
- Downtime minutes
- Stoppage count
- MTBF
- MTTR
- Top reason %
- Cumulative Pareto %
Maintenance
- Pending
- Scheduled
- Overdue
- Completion rate %
- Avg adherence %
Fleet
- Devices online / offline
- Machines tripped
- Ideal cycle time
- Work order progress %
Roles
Everyone sees exactly their job.
Supervisors are pinned to a single machine and land on it at login — no menu hunting on a shop-floor tablet. Reports are deliberately hidden from the supervisor view.
Company Admin
Every machine in the plant, work orders, all five reports, maintenance schedules, employees and company settings.
Supervisor
One assigned machine, opened straight to it: live health, shift summary, start/stop, timeline, stop reasons and maintenance tasks.
Made for the shop floor
- Mobile-first layout with a bottom nav bar; full sidebar on desktop
- Day-by-day shift summary with previous/next stepping
- Open-maintenance badges follow you through the navigation
- Every date, time and shift boundary computed in IST — no timezone drift
Your data
It stays in India, and it stays yours.
Production data tells anyone who reads it exactly how your plant runs. It is treated accordingly.
Hosted in India
Your plant data is stored and processed on servers located in India. It does not leave the country.
Backed up daily
Your plant history is kept on storage dedicated to your installation and backed up automatically every day.
Encrypted end to end
Every device authenticates with its own certificate, and all traffic between the machine and the platform is encrypted.
Scoped access
A company can only ever read its own machines — enforced on the server, not just hidden in the interface. Passwords are stored hashed.
Built for Indian manufacturers: every date, time and shift boundary is computed in IST, energy cost is in ₹, and the platform runs on infrastructure hosted in India. No data crosses a border to make a report.
Questions
The ones we actually get asked.
Will this work on my old machine?
Yes — that's the point. The kit reads electrical and production signals at the machine. It doesn't need a modern PLC, a data port, or cooperation from the machine's manufacturer.
Do my operators have to learn software?
Barely. On a connected machine, runs and stops record themselves. The operator's only job is tapping a red block and choosing the reason. Supervisors log in to one machine and land straight on it.
How is this different from a full MES?
An MES is a multi-month project that runs your plant. SIM-Kit measures it. It answers the four questions that pay for themselves first — how much did we make, how long were we down and why, what did it cost in power, and are we actually doing the maintenance.
What if the machine loses connectivity?
Readings are cumulative counters, so a gap doesn't corrupt your totals — the numbers reconcile once the device reconnects. Firmware updates queue for offline machines and start automatically when they come back online.
Can we still record things by hand?
Yes. Manual start/stop with work order, produced and rejected quantities is fully supported, and any timeline segment can be added, edited or corrected after the fact — including on connected machines.
Where does our data live?
On servers in India, on storage dedicated to your installation, backed up automatically every day. It does not leave the country. Each device authenticates with its own certificate and can only write its own readings, and a company can only ever read its own machines.
How many machines can it handle?
The platform is built and tuned for deployments in the hundreds of machines per installation.
See it on your machine.
Tell us what you run and we'll show you exactly what SIM-Kit reads off it — the timeline, the OEE, the energy cost, the Pareto.