You Shouldn't Have To Guess What's Happening In Your Plant

Operational data exists everywhere, but rarely in a form you can trust or act on. We help you model your process, connect your systems, and turn raw data into information you can use to solve real problems.

Find Your Problem And See How To Solve it

From our experience, the solution is often simpler than it looks once you can clearly see what’s happening.

SCRAP & Material
Losses

Why are we wasting material?

Key Events

  • Scrap by process step
  • Rework & recovery
  • Raw material changes
  • Changeovers and setups

Key Metrics

  • Scrap rate
  • Loss by reason/category
  • Financial losses
  • First pass yield

Scrap Isn't Random, It's Repeatable

Scrap is driven by specific process conditions across shifts and assets. You need visibility into when and why it occurs so you can eliminate it at the source and reduce material and production losses.

OEE Is Only As Good As The Events Behind It

OEE is often built on incomplete or assumed data. You need to model availability, performance, and quality as real production events so you can trust the number and act on what’s driving it.

OEE & Utilization
tracking

What's really driving our OEE numbers?

Key Events

  • Planned vs unplanned DT
  • Performance loss
  • Scheduled or planned time
  • Changeovers and setups

Key Metrics

  • OEE
  • TAED
  • TEEP
  • Utilization %

Continuous
improvement

Where should we focus our efforts?

Key Events

  • Constraint active time
  • Production losses
  • Starved/blocked states
  • Reduced speed intervals

Key Metrics

  • Constraint utilization
  • Schedule divergance
  • Total loss time by category
  • Throughput at constraint

Improvement Starts With Knowing What To Fix

Without clear visibility into losses and constraints, improvement efforts become guesswork. You need to model and measure real production events so you can focus on what will actually increase throughput.

Turn Downtime Data Into Insights

Most systems capture when production stops, but not what actually caused it. You need to model downtime as structured events so you can uncover root causes and eliminate repeat failures. Even if you are already capturing downtime, there is more work to be done.

Downtime
Analysis

What's the real reason for every stop?

Key Events

  • Downtime incidents
  • Microstops
  • Scheduled vs unscheduled
  • Operator-entered reasons

Key Metrics

  • Downtime by reason
  • Top loss categories
  • Financial impact
  • Durations and frequencies
Model your process hierarchically
Connect to any data source
Flexible time-series aggregations
Model events with full context
Build The Solution Your Process Actually Needs
Build advanced custom calculations
Define limits, targets, thresholds
Roll up data across time
Scale fast with reusable templates

Build The Solution Your Process Actually Needs

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— don't let someone else dictate your data model.

Energy &
Utilities

What is driving our utility costs?

Key Events

  • Peak demand events
  • Startups & shutdowns
  • Utility interruptions
  • Product runs & process steps

Key Metrics

  • Energy per unit produced
  • Cost per batch
  • Peak demand
  • Load profiles

Energy Costs Aren't Just A Utility Problem

Spikes in energy use are often tied to how production is running. You need visibility into when and where energy is consumed so you can reduce cost without impacting output.

Hitting Targets Shouldn't Feel Uncertain

When performance isn’t tied to what’s happening on the floor, it’s hard to explain results. You need to connect production data to real events so you can manage output with confidence.

Production
Performance

Are we hitting our production targets?

Key Events

  • Run / Stop / Idle states
  • Production starts & stops
  • Batches and changeovers
  • Reduced speed

Key Metrics

  • First pass yield
  • Throughput
  • Schedule compliance
  • Constraint utilization

Asset
reliability

How reliable are our critical assets?

Key Events

  • Faults & alarms
  • Maintenance interventions
  • Unplanned downtime
  • Mean time between failures

Key Metrics

  • MTBF & MTTR
  • Downtime by asset
  • Hour duration
  • Total starts/stops

Most Failures Aren't Random

When failures aren’t tied to real operating conditions, the same problems return. You need to connect faults and downtime to production events so you can address the root cause.

Find Out Where Your Quality Issues Really Are

Catching defects at the end of the process is too late. You need to connect quality outcomes to real production events so your team can identify and eliminate the sources of variation.

Quality
PERFORMANCE

Why are we producing defects?

Key Events

  • Quality inspections
  • Rejects and rework
  • Process deviations
  • Raw material changes

Key Metrics

  • First pass yield
  • Rework rate
  • Defects by process step
  • Financial losses

Operator
performance

Are operators set up for success?

Key Events

  • Running in manual state
  • Rate reductions
  • Shift handoffs
  • Changeovers and setups

Key Metrics

  • Task completion time
  • Variability by shift
  • Adherence to plan
  • Operator utilization

Your People Are Key To The Process

Ensure your team has the right data to guide their decisions and learn from each other. Operators need to know what works and what doesn't, and must have faster feedback loops.

Better Data, Better Decisions.

At Flow Software, we exist to give teams decision-making superpowers.

We’re a driven, curious, and dedicated global team, committed to turning raw data into actionable insights since 2011.

Guided by our core values, we empower businesses to elevate their operations, embrace innovation, and achieve lasting success. Remote by design and lean by choice, we deliver solutions that simplify complexity and inspire smarter decisions.

6500 River Place Blvd
Building 7, Suite 250
Austin TX 78730

PO Box 161451
Austin TX 78716
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