Manufacturing intelligence, built on the floor
One dashboard for OEE, downtime, maintenance, quality, energy and materials — live from your PLCs, on every screen in the plant.
No signup. Four simulated plants, one-click role logins, real screens.
Every plant I've worked in runs on an endless stack of Excel worksheets — one for production, one for downtime, one for scrap, all filled in at shift end from memory, all disagreeing with each other by Friday. That inefficiency is why FloorVision exists: the numbers come off the machines, not off a worksheet.
The other half is maintenance. The talent isn't what it used to be, and the commitment to take care of the machines isn't either. You can't hire back the Tech who could hear a bearing going — but you can put sensors where that ear used to be. More sensors means more opportunity to watch the machines, and to catch things while they're still cheap to fix.
Product
Every screen below is a real screenshot from the live demo. Click any of them to look closer.
The whole plant on one page: which lines are running, which are down, and for how long.
OEE broken into Availability, Performance and Quality, by line, shift, day and month.
Every stop is captured automatically the moment the run signal drops. Operators only have to say why.
Breakdowns become work orders on their own. Techs close them from a phone.
Put a TV on the wall, point it at a URL, walk away. No login, no mouse, no upkeep.
Every sensor you feed it, next to its setpoint, with the deviation in plain numbers.
What the plant is burning and what it's about to run out of.
SIOP and forecast next to what the lines actually did, plus a morning briefing you can read in the truck.
How it works
Nothing exotic. Proven open-source pieces, wired together so they behave like one product.
We host and maintain the platform. Your plant just needs the edge gateway pushing data out — no servers to buy, patch or babysit on site.
Use the built-in maintenance module on its own, or push work orders and production counts into what you already have.
Standard databases you can query directly. Export anything, any time. If you leave, you take it with you.
Industries
The four plants in the demo are modelled on real processes. Each measures throughput in its own units — FloorVision speaks them.
Northgate Extrusion in the demo. Rate from the line encoder or scale, changeovers, die swaps, melt temps and screw amps alongside.
Summit Molding. Rate is cavities × cycle time, straight from the press. Short shots and cycle drift show up as quality and performance losses.
Riverbend Carpet Mills. Linear yards per hour by tufting line, with style changes, creel stops and seconds tracked as reasons.
Harbor Corrugated. Thousand square feet per hour on the corrugator and converters, with order changes and warp counted properly.
Food, metals, packaging, wire — if a PLC runs it, we can measure it. And it goes far beyond dashboards — see how custom modules work.
Custom modules
FloorVision gets you off the ground with everything you saw above — but the reason plants keep us around is what comes next. We tailor it to how your plant actually works. Tell us an area you need help, and we build the module that fixes it.
Every week, someone downloads the same ERP report. Same columns deleted, same slicing, same Pareto, then it gets formatted and emailed out for review. Forty-five minutes of work nobody wants, done exactly the same way, every single time.
So we build you a module for it. Upload the file — or let FloorVision pull it on schedule — and the module deletes, slices, Paretos and formats it the way you always do. What was a 45-minute task you hated is done in 30 seconds: reviewed, downloaded, delivered.
Day one you get the full platform. From there we shape it to your wants — your codes, your reports, your workflows, your weird machine.
A report you re-build weekly. A paper form the QA tech re-types. A number three departments compute three different ways. Name it — that’s a module.
You’re not filing tickets into a product backlog. You’re talking directly to the person who built the platform — the brains behind all of it — providing solutions: scoped, quoted and delivered.
Alerts
Most systems log a problem and wait for someone to look. FloorVision escalates until a human reacts — from a quiet bell to a phone buzz to taking over every screen on the floor.
Every event lands in the notification bell — silo refills, work orders raised, lines back up. The quiet layer.
Breakdowns, new work orders and daily summaries pushed to the right phones and inboxes the moment they happen.
For the ones that can’t wait: every TV board and line station in the plant dims and goes full red alert until it’s acknowledged. Nobody says “I didn’t see it.”
Pricing
Priced per plant, not per user. Every tier includes the live demo's full feature set for the lines it covers. Final quotes depend on line count and integrations.
$1,250/mo per plant
Onboarding $5,000 one-time
$2,950/mo per plant
Onboarding $9,500 one-time
from $6,500/mo
Onboarding quoted per site
Add-ons: custom module development $150/hr · edge gateway hardware $2,400 one-time per line. Perpetual licence available — ask.
FAQ
Allen-Bradley (EtherNet/IP), Siemens S7, Omron, Modbus TCP/RTU and anything with an OPC-UA server. And the machines with no network — or no PLC at all — are not left out: we retrofit. A relay across the old “material out” stack light turns a 40-year-old lamp into a live alert. A current clamp on the motor tells us run/stop and load. A photo eye counts parts. A dry contact on a door, a 4–20 mA transducer on a pressure line — if it has a wire, it can report. That is often where the biggest wins are, because those are the machines nobody has ever measured.
Usually just one edge gateway per line ($2,400) or per cell — that's the only box that lives in your plant. No new sensors are required to start; the PLC already knows when the line is running and how many parts it made. Add sensors later if you want energy or process data the PLC doesn't have.
We do. FloorVision runs on our own infrastructure — you open a browser, and we handle the servers, updates and backups. Your plant's gateway pushes data out over an encrypted connection; if the internet drops, the gateway buffers and catches up when it's back. Enterprise customers get a dedicated instance on their own domain.
You do. It lives in standard databases (InfluxDB and MongoDB) that you can query with any tool. Exports are built in. If you ever stop using FloorVision, you keep every record, and Enterprise agreements include source escrow.
The honest answer: it depends on whether your machines are already talking. If your PLCs already publish data — tags mapped, sensors wired — the software side is easy: dashboards come up in days. Most plants aren't pulling anything yet, and that's the real work: plan a week or two of getting the data flowing — identifying PLC tags, adding sensors where there are none, and wiring the gateway. Once the data is moving, configuring lines, reason codes and users is a day, plus a couple of shifts of watching it run and operator training.
For many plants, yes. The maintenance module covers work orders, PMs, MTTR/MTBF and PM compliance, and it raises work orders from breakdowns automatically — something most CMMS packages don't do. If you have a CMMS you like (ManagerPlus, for example), we integrate with it instead.
Each plant runs its own instance so a network outage in one never affects another. The Enterprise scorecard rolls them up: OEE, downtime, maintenance backlog and energy across sites, side by side, with the same definitions everywhere.
You talk to the person who built it. Starter includes email support with next-business-day response; Plant adds phone support; Enterprise has an SLA. Updates are included in the subscription and are applied outside production hours.
Book a demo
Thirty minutes on a call. Bring a line you'd like to see measured; I'll show you what it would look like in FloorVision and what it takes to hook up.
Robert HaussPrefer to poke around first? Open the live demo — no signup, four plants, one-click role logins.
