The calculations
Totals, run rates, uptime and yield, worked out cell by cell. Some formulas reach into other tabs. A few were typed over by hand one busy week and never put back.
Spreadsheet to system
The spreadsheet that runs your plant, rebuilt as a system.
Your shift report already holds the plant's calculations and rules. We rebuild it as a governed web app, fed straight from the machines and your ERP exports, with a live shop-floor dashboard on top.
Show us the spreadsheetRead-only to the controls. You own the code and the data.
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Plant viewSample
Day shift, 4 lines
Good parts4,296
Downtime212m
Uptime89%
OEE66%
The same shift, as a spreadsheet and as a dashboard. Illustrative sample numbers only.
Inside the file
What the spreadsheet is really doing
Look past the colors and the tabs. The file that runs the plant is doing three jobs at once, and only one of them is arithmetic.
The rules
Which stops count as planned. What counts as a good part. When a shift starts and ends. The ideal cycle time for each part. Your standards live here, in a tab most people never open.
The one person who knows them
Someone built this file, and they are the only one who can explain a total that looks wrong. When they are out, the report waits. When they move on, the logic goes with them.
None of this is a mistake. It is the business logic of your plant, and it has outgrown the file it lives in.
Where the numbers come from
Two sources, one system
The machines know what happened: when a press ran, when it stopped, how many parts came off. ERP and your standards know what should have happened: the shift calendar, the part on the schedule, the ideal cycle time.
A number you can defend needs both. OEE is the clearest case. The controls supply availability and counts, but they have no idea what the shift calendar says or what a part's ideal cycle should be. Those normally sit in ERP or in your written standards. We connect both sides and hold them in one place, with one set of definitions.
The link to your machines is read-only. It listens to the controls and has no way to send a command back.
From the floor
PLCs, HMIs, Kepware and OPC servers.
Machine statusPart countsStopsCycles
From the office
ERP exports, standards and the sheets around them.
Shift calendarsIdeal cycle timesPart numbersStop codes
One system
One set of definitions, checked and owned by your team. The reports, the apps and the plant dashboard all read from it.
The rebuild
Rebuilt with guardrails
A spreadsheet is quick because nothing gets in the way. The rebuilt version stays quick for the people who use it every shift, and adds the checks a finance review or a quality audit expects to find.
Everything we build runs in your environment and belongs to you: source code, data and systems alike. Ongoing support is there if you want it. It is not a licence.
A web app
People open a page, not a file on a shared drive. There is one current version, so nobody has to work out which copy is FINAL.
An audit trail
Every entry and every change records who made it and when. When a number moves, you can see why.
Permissions
Operators enter what they own, supervisors approve, managers read. Each role sees and changes what it needs, and nothing more.
Rules you approve before anything is rebuilt
We write out every calculation and rule the spreadsheet carries, in plain words. You review them and sign off. Only then do we build.
The plant dashboard
The dashboard on top
Once the numbers sit in one governed system, the shop-floor dashboard is the view on top of it. We connect PLCs, HMIs, Kepware and OPC servers, plus the spreadsheets around them, into a live plant screen.
Supervisors see the shift while it is still running. Managers see the same numbers the reports use, because they come from the same place.
We start with the few views that matter most, tied to a bottleneck, a defined measure and the person who owns it.
| On the screen | Where it comes from |
|---|---|
| Machine status | The controls: running, idle or down, by work center. |
| Part counts | Machine counters, split by shift and part number from ERP. |
| Run rates | Machine cycles, compared with ideal cycle times from your standards. |
| Uptime and downtime, with reasons | Stop events from the controls, with reasons entered on the floor or at the HMI. |
| Scrap | Rejects, if the controls or your quality records already count them. |
| OEE and trends | Both sources together, tracked across shifts, days and weeks. |
Capabilities
What else we build around the data
The shift report is often the first file. The same approach works for the rest of the work that runs on copies, exports and retyping.
Spreadsheets, rebuilt
The spreadsheets a process depends on, turned into governed web apps that log each change, limit who can edit and follow rules you signed off.
Automation and integrations
Work passes between systems on its own, so nobody retypes an order, a count or a status.
A structured data layer
Defined plant and business data, with APIs that other tools and teams can read from.
Reporting that assembles itself
Shift, weekly and month-end reports build from the system instead of a copy and paste session.
Custom internal tools
Small, purpose-built apps for jobs no packaged product quite fits, shaped around how supervisors and operators actually work.
Ongoing support
Help to extend and look after what we built, when you want it. Optional, and never a licence.
Who does the work
The people who scope the rebuild are the people who build it. Behind that sits more than 20 years of building systems for businesses where operations carry most of the weight.
- PLC and controls engineering, Allen-Bradley included
- ERP advisory
- Integration work and data architecture
- Frontend and backend software
Which spreadsheet does your plant run on?
Tell us about the file: what it tracks, who keeps it and where its numbers come from. We will tell you plainly whether a rebuild makes sense. If the sheet is doing its job, we will say that too.
Show us the spreadsheet
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