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Shopfloor digitization with Simplifier

Increase your OEE
by 5% to 15%

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Why does Shopfloor digitization often fail?

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Sticking to the manual status quo

  • Media disruptions between paper, Excel and isolated solutions prevent end-to-end digitization

  • Lack of real-time transparency: KPIs are outdated, reactions take too long

  • Manual data entry causes errors, effort and downtime

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Inflexible Shopfloor solutions

  • Standard software enforces processes instead of mapping real requirements
  • Updates and adjustments are limited and often cause new problems instead of progress.
  • Isolated solutions prevent integration beyond the Shopfloor
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Mindset slows down progress

  • Decisions are postponed, responsibilities are unclear

  • Pilot projects simulate progress, but are not scalable

  • Existing system boundaries are accepted and prevent true digitization

Did you know?

65% OEE is average in the German manufacturing industry. World-class is 85%+. This 20 percentage point gap costs a medium-sized plant €2-5 million in opportunity costs per year.

Improve KPIs sustainably

Through digital solutions – perfectly tailored to you.

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Tailor-made instead of off the peg

No two Shopfloors are the same. That’s why we have developed templates that we adapt to your individual requirements – not the other way around. This way you avoid compromises, workarounds and later restrictions.

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What is sufficient today will become a problem tomorrow. Individual solutions grow with your processes, can be expanded and remain stable in the long term – even if requirements, quantities or structures change.

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Your processes set the pace

Standard software is based on assumptions, not on your reality. We digitize your historically grown Shopfloor processes exactly as they work today – without detours, without conversion, without frictional losses.

KPI improvements from practice

Top 5 Shopfloor Use Cases

1. fault management / incident management

Eliminate downtime faster – reduce MTTR by 25-40

  • Mobile fault detection with GPS, photo, video

  • Push notifications to the right technician

  • Central database for Pareto analysis
  • Preventive measures based on data

Impact KPIs

  • MTTR: -25-40% (e.g. from 60 → 36-45 min)
  • UDT: -15-25%
  • Reason code coverage: >85%
  • Savings of 50,000 – 200,000 € per year

Customer opinion

“With Simplifier, we can now see incidents in real time. The central database helps us to identify high-risk production phases and take preventative action.”

2. digital Shopfloor Management with Boards

Increase OEE through real-time transparency

  • Interactive Shopfloor boards on large touchscreens
  • KPI reporting in real time (OEE, availability, performance, quality)
  • Issue tracking with clear responsibilities
  • Data integration from SAP, MES, machines, documents

Impact KPIs

  • OEE-A: +3-8 percentage points
  • Plan fulfillment: +7-10 percentage points
  • Reporting time: -80% (5 days → 1 day)
  • 200,000 – 450,000 € per year

Customer opinion

“Managers save a lot of time as manual reports no longer need to be created. All employees have direct access to up-to-date information.”

3. BDE / digital workbench

Increase performance – process production orders end-to-end

  • Central registration/deregistration of production orders
  • Setup/personnel/machine times automatically recorded
  • Automatic SAP feedback without media discontinuity
  • Prioritized order list and multi-machine operation

Impact KPIs

  • Performance: +3-7 percentage points
  • Changeover time: -15-25%
  • Data completeness: >95%
  • 180,000 – 400,000 € per year

Customer opinion

“With Simplifier, all the necessary functions could be bundled in one application. Parallel time recording now brings clear efficiency benefits”

4. digital work instructions

Increase quality – improve FPY by 3-7 percentage points

  • Step-by-step instructions with images/videos/AR
  • Guided editing – no step can be skipped
  • Automatic quality checks integrated
  • Dashboard integration for KPI tracking

Impact KPIs

  • FPY: +3-7 percentage points (e.g. from 88% → 94%)
  • Scrap rate: -30-50%
  • Onboarding time: -50-80%
  • 60,000 – 160,000 € per year

Customer opinion

“97% reduction in errors by avoiding incorrect entries. New employees are trained more quickly.”

5. smart maintenance / maintenance dashboard

Preventive instead of reactive – increase OEE-B by 5-12 percentage points

  • Real-time monitoring of machines and systems
  • Definable threshold values for critical parameters
  • Push notifications when exceeded
  • Trend analysis for preventive maintenance

Impact KPIs

  • OEE-B: +5-12 percentage points
  • PDT: -20-30% (optimization of planned downtimes)
  • MTBF: +25-40%
  • Breakdown reduction: -40-60%
  • 350,000 – 700,000 € per year

Customer opinion

“Machine downtimes are avoided because the systems are continuously monitored. The configuration level is 99%.”

References

Some of our Shopfloor customers

Bürkert

Digital Shopfloor Management Board

KPI improvements:

  • Managers save considerable time (no manual reports)
  • 100% real-time transparency
  • Continuous process optimization

SAERTEX

Loading control

KPI improvements:

  • 9 days time saving/month
  • 97% Troubleshooting
  • 93,000 € savings/year

HF Mixing Group

BDE

KPI improvements:

  • 1,600 working hours saved per year
  • Up to 10% increase in production capacity
  • Lower costs for maintenance, support and IT

Felix Schoeller

Digital goods receipt

KPI improvements:

  • 55% increase in data quality
  • 100% more transparency
  • 70 days time saving/year

Hako

Digital Shopfloor Management

KPI improvements:

  • Increased transparency in assembly plants
  • Measure team KPIs in one tool
  • Easy access to assembly documentation

Would you like to increase your OEE by 5-15%?

Invest 30 minutes to find out:

  • How we can increase your OEE
  • Which solutions can add the most value to your setup
  • How quickly initial successes can be measured

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