Multi-faceted production support tools utilizing proprietary wireless technology coupled with an ultra-reliable, advanced, stand-alone electronic platform and global first Productive Downtime algorithms.

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Predictor Power IO


Power IO

Globe GlobeLive



Product Description and Operation

Productive Downtime

We utilize a system's constraints, over-capacity and acceleration capability, to predict the location and magnitude of Productive Downtime at workstations, in a coupled manufacturing system.

Green alert light. The machine may be stopped without affecting overall line performance and at no cost to line efficiency.

In this context we define Productive Downtime as the time available for a production machine operator to stop his machine due to inherent spare capacity or a stoppage at the current line constraint (bottleneck), without affecting the overall performance of the production line.


The magnitude of Productive Downtime available at a given workstation is communicated to the operator utilizing our proprietary wireless technology coupled to our user friendly Predictor HMI.

We identify four major categories of Productive Downtime.

  • Sleep Productive Downtime: The minimum amount of time an operator has when the production line is asleep (no product on the entire line).
  • Start-up Productive Downtime: Knowing when product will reach each point of production during the startup cycle, allowing operators to prepare timeously.
  • Dynamic Productive Downtime: Utilizing spare machine capacity and current accumulation levels.
  • Static Productive Downtime: Created by break downs or stoppages on other machines utilizing estimated time assigned to the stoppage, aka Breakdown Productive Downtime.


Data acquisition platform

The platform was developed as a stand-alone system that can capture production line data at source with an uptime and reliability of above 99%.

The platform does not require support from IT specialists. It is a machine, and like other machines on the production line, it can be serviced and maintained by technicians (the platform has no scheduled maintenance requirement).


The Globe device is typically located in the Supervisors office close to the production line. The device is powered by PoE Ethernet and can be connected directly to the customer network or to a PC. The Globe communicates with all the Predictors on the production line utilizing our wireless network.


Dynamic Production Reporting in Realtime

We have developed an innovative approach to realtime production reporting, eliminating the need for proprietary software solutions. The cross-platform desktop-PC application GlobeLive gives visual insight into the production process in real-time.



Downtime Analyzer

The Downtime Analyzer only focuses on machine downtime that has a direct cost to production line efficiency.

Utilizing our advanced Productive Downtime algorithms, we dynamically track the location of the Bottleneck Machine during production and flag its alert light yellow, signalling to the operator that he is the current bottleneck on the production line.


Amber alert light notifies the operator that he is the current bottleneck on the production line and should avoid stopping his machine as the stop will have a direct cost to line efficiency.

Should the Bottleneck Machine stop, it becomes the Constraint Machine. It is flagged red and a pre-programmed cause screen automatically pops up on the Predictor HMI.


Red alert light indicates that you are the Constraint Machine at a direct cost to line efficiency, start machine up as soon as possible.

The operator is prompted to select a cause followed by an estimated downtime (which is communicated to the other operators on the production line). Cause and actual downtimes are stored in the Globe device and can be viewed at anytime using a Web Browser.



Messaging combines both the proprietary wireless and GSM telemetry to communicate pre-programmed messages.

Message routing includes but is not limited to:

  • Operator to Operator
  • Operator to Supervisor
  • Operator to Maintenance
  • Operator to Predefined GSM number/s
Choose destination Select from the list You have a message
Send Send You have mail

Messaging dramatically improves response times to breakdowns and other issues on the production line that in turn helps to improve overall line efficiency.



The IPAV Systems Simulator is a realtime simulation that can emulate any production environment, utilising Predictors, IO devices, a Globe and GlobeLive.

Production line parameters and key machine characteristics are entered into each of our devices replicating different points of interest. This includes parameters such as product throughput rates and pack sizes.

When activated, the Simulator generates sensor input triggers at the in-feed and out-feed of each machine at the I/O level. Input triggers on the reject input are available at a given percentage of throughput, if required.

Time Between Failures and Time To Repair are configured and randomised to effect Operator Stops.

Simulation Mode is almost entirely decoupled from normal operation and is embedded in the firmware of the devices. The system as a whole operates as it would with live sensor inputs. Each machine is aware of its upstream and downstream neighbours in order to detect starving and buildback conditions and therefore invoke Machine Stops.

The IPAV Systems Simulator can replicate planned production line modification, providing true to life results and facilitating on-the-fly conveyor adjustments to refine the proposed modification.

Dynamic Production Reporting constantly calculates optimum accumulation capacities, utilization, machine speeds, Mean Time Before Failure (MTBF), Mean Time To Repair (MTTR), machine efficiencies and much more.

In Simulation mode, the Dynamic Production Reporting is useful to validate proposed line modifications.

Simulation Mode can identify excessive accumulation and/or lack of accumulation capacity, along with correct V-profile design, machine speeds, bottlenecks, etc.


Analysis and Visualisation

The GlobeLive software brings together the data captured at the Predictors and monitored by the Globe device. Here we can Analyse and Visualise the production process. The automatic Record feature of the software implies Playback. All data received is recorded and therefore may be played-back. Now we can Analyse and Visualise not just in real-time but at any time for which we have a recording.

Given that GlobeLive can operate off-line, ie. not connected to a Globe and/or production line, a recording may be played back anywhere.

In fact, we encourage this as a more efficient means of reporting. The advantages over static, snapshot, paper-based reports are clear. There is no means of input or modification of the data which means greater transparency in the reporting. We're reinventing reporting as what-you-see-is-what-actually-happened.

This creates many opportunities. Recordings are made on a shift basis with all data for a single shift in one file. This file and its playback requires no third-party software, only the GlobeLive application. Depending on the number of points of interest on the production line, the file size will vary, but is typically less than 3 Megabytes for an 8-hour shift on a line with 8 machines, for example. A reasonable size for emailing and local storage. Coupled with the ability to drop bookmarks into the recording, the reporting, analysis and visualisation of a shift is drastically simplified.

Analysis and Visualisation of Recordings serves a variety of purposes:

  • Highlighting Causes of Downtime with a view to targetting maintenance.
  • Tracking down incidents that occurred at a given machine at a given time and the circumstances that led up to them.
  • Locating efficiency problems and finding ways to adjust or improve them.
  • Identify accumulation capacity issues. By using our statistical calculation of Minimum Accumulator Level, which shows the levels required to absorb micro-stops, steps can be taken to either reduce micro-stops or adjust accumulation capacities.
  • Speed Loss. See which machines lost time and by virtue of being able to see what happened on the whole production line, pin-point the causes.
  • Efficiency Monitoring. Track OEE numbers or simply track actual vs targetted production over time.

The trend should be clear. The capability exists to help improve efficiency while its happening, in real time, or some time after the fact, for planning, maintenance or other purposes.

We've mentioned elsewhere that we don't charge extra for the GlobeLive software. Its a Java application that is bundled with our hardware as part of the product. It runs almost everywhere (we've tested it on Windows, Linux and Mac platforms). And that it doesn't require any third-party software (except for a Java runtime) or licensing fees. Well, we're mentioning it again.

There are many many more features. The GlobeLive software is constantly growing and evolving. As we learn more, we pass those upgrades on to you.