How it works

The plant looks after itself. Here is how.

ManufacSys™ reads from the machines and systems you already run, builds one live model of the plant, and acts on it under your control. No migration, nothing ripped out.

The four steps

From what the plant knows to what gets done.

01Connect

It reads from the SCADA, MES, historians, and sensors you already run, through their own interfaces. Nothing is replaced or migrated.

02Understand

It reads every signal as one plant. It knows which asset each one belongs to, what is current and what has gone stale, and where each reading came from, so it catches the trouble building across systems instead of missing it between them.

03Control

Before anything acts, it checks what it is allowed to do, who is asking, and what a person needs to sign off. Nothing reaches the floor outside those limits, and every step carries its evidence.

04Deliver

Then it acts where the work happens. A costed work order in your CMMS, a setpoint on the line, an answer for the operator, or a live view for the board, the moment you approve.

No migration, no rebuild, no new way of working.

The specialists

Purpose-built agents, each scoped to one job.

An agent is not a chatbot. It is a specialist with one job, a fixed set of inputs, and a fixed set of things it is allowed to do. Here is the shape of one.

AgentMaintenance

JobKeep the line running by catching wear before it fails.

ReadsVibration, current, temperature, and process data, plus the repair and failure history.

ReasonsRecognises the failure building across those signals, and tests the fix on a digital twin.

Can doRaise a costed work order and book a window. Nothing without your approval.

ReturnsThe recommendation, the window, and the evidence behind it.

The six specialists

Maintenance predicts failures and raises the work order.

Quality catches defects in process and traces the cause.

Production holds cycle time and sequences the line.

Scheduling balances demand, people, and machine health.

Energy trims usage and hits your Scope targets.

Executive turns the whole plant into a board-ready view.

Answers

Ask your plant a question.

Every answer traces back to where it came from, so you can always check it. Open a question to see what it followed.

The infeed drive tripped on overload at 22:06, six minutes after the shift change, while the line was still running the day shift's speed against a colder machine.

SCADADrive current on L4-INF-01 climbed from 41 A to 63 A over four minutes, then tripped at 22:06.

SCADAZone 2 sat 18 °C under the night recipe's target at that same moment.

MESThe 22:00 job change loaded the night product. The speed setpoint stayed on the day run's value.

HistoryTwo earlier trips on this drive, in March and in June, followed the same cold start.

ActionRaised for approval: hold the speed setpoint until Zone 2 reaches target on a night start.

Three. The nearest is the spindle bearing on CNC-14, about two days from the point where this bearing usually goes.

SensorVibration at the bearing's fault frequency has doubled on CNC-14 across nine days.

SCADAThe spindle is pulling more current for the same cut, the same wear showing up a second way.

HistoryOf four past repairs on this bearing, the last two ran this pattern for eleven and thirteen days before failing.

TwinReplaying the current load on the digital twin puts the failure inside 48 hours.

ActionRaised for approval: a costed work order on Tuesday's planned stop, ranked against the other two.

At 14:20 on Tuesday, when the sealer's dwell time was cut by 0.2 seconds to recover cycle time. The seam has been sliding toward the limit since.

MESSeam strength readings start sloping down from the run that began at 14:20 on Tuesday.

SCADAA dwell change from 1.4 s to 1.2 s was written to the sealer nine minutes before that run.

WorkbookThe yield sheet shows scrap on Line 3 rising from that shift onward.

DocumentWork instruction WI-114, section 4, sets the dwell floor for this film at 1.35 s.

ActionRaised for approval: hold the next lot, put the dwell back above the floor, and flag the runs made since.

Short runs. Line 6 spends about a fifth of its running hours in changeover and warm-up, drawing close to full power while packing nothing.

MeterLine 6 draws 0.68 kWh per unit. Line 5 draws 0.21 on the same product.

SCADACompressed air and the heat tunnel stay on through a changeover, near full load with nothing moving.

MES14 changeovers on Line 6 last week against 4 on Line 5, from the way the orders were sequenced.

WorkbookThe cost sheet prices that idle draw at the peak tariff, because most changeovers land inside the peak window.

ActionRaised for approval: group the short runs, and drop the tunnel to standby between orders.

Illustrative examples, not real plant data.

Vector Sheets

The agent that understands your spreadsheets.

Most of a plant's real numbers, yield, energy, and cost, live in a handful of Excel workbooks, spread across tables and tabs, built by hand over years. Vector Sheets reads those workbooks, runs the calculations, and works out how the tables relate, not just the cells in front of it.

plant-metrics.xlsxRead only

YieldEnergyCost

Line	Units	Scrap	kWh	kWh/unit
Line-3	12,400	210	5,208	0.42
Line-4	8,600	395	3,397	0.40
Line-5	24,100	205	5,061	0.21
Line-6	5,400	165	3,645	0.68

TraceYield!E2Energy!B14Cost!D7

Your numbers live in complex workbooks.Yield sheets, energy trackers, and cost models, often many tables across many tabs, built by hand over years.

The answer spans sheets, not cells.The real question usually crosses several tables that reference each other from different sheets. A single formula never captures it.

It answers questions and does the math.Ask in plain language. Vector Sheets runs the query and the calculation across the workbook, the way a careful process engineer would.

It understands the relationships.It works out how a table on one sheet connects to a table on another, so the numbers line up instead of contradicting each other.

Integrations