Optimize Manufacturing Processes and Boost Factory Performance

Optimizing manufacturing processes is essential for boosting factory performance in today’s increasingly complex and competitive environment. Tight margins, strict deadlines, waste reduction, energy efficiency, reducing downtime, maintaining quality, and finding the right personnel, are all pressing challenges. Success depends on knowing where to focus. Success depends on knowing where to focus.

With deep insights into machinery, processes, and personnel, innius helps factories to boost performance by:

1. Raising efficiency

2. Reducing downtime

3. Adopting digital Condition-Based Maintenance

4. Enhancing quality and reducing waste

5. Maximizing capacity utilization

6. Engaging personnel

7. Reducing energy usage

What’s behind your inefficiencies?

Where’s your factory losing time?

Too much or too little maintenance?

Why does one shift outperform another?

What’s driving up energy costs?

What’s causing hidden waste?

Would better data change your plans?

1. Raise Manufacturing Efficiency with Process Insights

Maximising manufacturing efficiency requires raising output while minimising inputs such as ingredients, operational technology, personnel, time, and energy.

The challenge plant managers face is identifying the root causes of inefficiency and then accessing their true impact. Issues hidden within complex workflows, production slowdowns, and idle time often go unnoticed or remain unexplained.

Tools like the OEE Drilldown Report and Capacity Utilization KPI can highlight where bottlenecks and inefficiencies occur. Comparisons can also be made with the Batch Report and shift analysis. Thereby allowing you to identify inefficiencies as shift-specific, recipe variations, or machine underperformance. This helps you standardise best practices and make better decisions when faced with competing efficiencies.

Discover more about innius’ OEE Software >>

2. Reduce Costly Downtime

Unplanned downtime can severely impact profitability. But knowing exactly when, why, and how long production has stopped is often unclear.

The innius platform combines automatic downtime detection with manual and automatic categorisation of downtime causes. These insights are presented in the Downtime Report, either based on shift performance or as a Pareto diagram. This enables plant managers or continuous improvement specialists to identify recurring issues, whether related to materials, machines, or staff, and intervene to minimise disruptions.

3. Use Digital Condition-Based Maintenance to avoid Disruptions

Too much maintenance wastes time and money. Too little leads to unplanned breakdowns. The key is to conduct maintenance just at the right time, and this is what Digital Condition-Based Maintenance, supported by innius, is designed to achieve. By monitoring machine sensor data in real time, innius can send alerts, automatically assign tasks, and provide dashboard overviews to give maintenance teams the insight they need to conduct maintenance in a timely, efficient, and cost-effective manner; to minimize unnecessary downtime.

The innius platform also tracks the industry-standard KPIs such as Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR). Together with the Downtime Report, this provides highly accurate reporting on maintenance operations, and their impact upon factory performance.

Discover more about innius’ approach to Maintenance >>

These companies already work with innius®

4. Enhance Product Quality and Minimise Waste

Product quality issues not only lead to waste but also damage customer trust. Without data supported facts, it can be difficult to identify which causes are having the most impact. Quality problems could be caused by all manner of issues, such as incorrect machine settings, operator errors, ingredient quality or recipe specifications.

innius supports quality management with tools like real-time sensor monitoring, automatic alerts, factory floor dashboards, and the Quality Report. These features enable both quick responses at the operational level to emerging situations and after-the-fact analysis for management.

The innius insights help correlate quality issues with specific machines, shifts, materials, or environmental conditions. This means faster root-cause analysis, fewer rejected batches, and better overall quality.

Discover more about innius’ approach to Quality >> and Food Waste >>

5. Optimise Manufacturing Capacity Before Expanding

Is your current production capacity fully optimised? Or is it time to scale operations?

innius provides a clear view of actual versus potential performance through KPIs like Capacity Utilization and reports such as the OEE Benchmarking Report. These tools allow factory owners and plant managers to assess utilisation rates and uncover hidden capacity. Decisions about capital investments can then be made based on solids data, not assumptions.

6. Engage Personnel with Data Insights

People are essential to the success of your factory’s operations. Providing them with the right tools and transparency is important to foster a positive culture of continuous improvement and recognition.

At the operational level, innius’ factory floor dashboards and apps give operators with the real-time insights they need, to warn of emerging problems before they escalate. This empowers operators by giving them control and immediate feedback on the impact of their actions.

At the management level, innius offers analysis into shift performance and operator-influenced variations in quality. This helps plant managers make better decisions, regarding shift planning, training, and rewards.

7. Reduce Manufacturing Energy Usage and Costs

Energy consumption is a significant operational cost and environmental concern. Without energy transparency, energy-saving efforts are based on guesswork. Which machines, lines, or shifts consume the most? innius provides a powerful solution with its energy monitoring capabilities. By tracking real-time energy consumption at the machine and line level, and correlating it with production data, innius uncovers hidden inefficiencies. The Energy Efficiency KPI provides a clear benchmark, helping you set targets and monitor progress. innius also supports energy-efficient decision-making through reports such as the Sensor Comparison Report, which allows manufacturers to compare energy usage under different conditions, shifts, or process recipes.

Discover more about innius’ approach to Energy Saving >>

Why innius?

A scale-up approach

Start with one machine and add more as and when you need. No complex IT integration project is required.

Hardware independence

Connect new and old machinery of different brands via Ewon or Ixon devices. Allowing you to upgrade your existing factory to Industry 4.0 level.

Designed for ease of use

With the correct information to hand, you can connect a machine yourself in as little as 90 mins. Start today to experience it!

Seamlessly integrate with other software

Innius seamlessly integrates with your digital ecosystem through APIs and webhooks. Share data with analytics tools such as Power BI and trigger tasks in EAM and MMS software.

Not enough time? No problem!

Innius consulting can help connect your machines to innius, analyse data and optimise your machines.

Frequently asked questions

Hopefully you can find any answers you need here, otherwise feel free to contact us.

How can I connect my machines to innius?

If your machines generate a data stream and can be connected to the internet, normally via a PLC and an Ewon Flexy or Ixon modem, then they should be innius capable.

To help you, an Innius Feasibility Study is available, find out more on our Getting Started page.

Do I need any other hardware, once my machines are connected?

innius is a cloud computing based service, so there is no requirement for on-premises servers. Just a mobile devices or a desktop computer to work with innius.

Can innius data be shared?

Yes, through the trusted relationships and machine sharing system, it is possible to share selected data with other entities. For example: a factory wants to share machine performance data with a machine maintenance company.

Who owns the data?

You remain the owner of all data generated. Innius will not share it.

What about security?

The main thing to consider is that innius only reads your machine data, it can’t send anything back to your PLC or machines, which obviously has huge security advantages.

In addition to that a number of industry standard security steps have been taken. These are fully detailed in the Knowledge Base. Or if you want to know more talk to us.

What is the pricing model?

innius operates on a monthly subscription pricing model, giving you access to all the apps. The cost depends mainly on the data usage in addition to a number of other factors. Please get in touch to talk about your specific needs.

My production line is a mix of both hi-tech and older machinery. Isn’t that a problem?

No, you don’t need to connect everything in a production line. innius can deal with individual machines.

Can I connect innius to other software?

Innius seamlessly integrates with your digital ecosystem through APIs and webhooks. Share data with analytics tools such as Power BI and trigger tasks in EAM and MMS software.

Richard Crowter, UX Designer & Marketing Coordinator at innius

Curious what innius means for your business?

This is Richard, he’s happy to advise you! Please fill out the form and he will be in touch!