Zometric Live Dashboards

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Zometric Live Dashboards decide what every operator, supervisor and plant head sees when they look up. Drag-and-drop dashboards aggregate every part of the operation, quality, production and maintenance, into the view each role needs, self-updating around the clock in 100+ languages. Build any view from one designer: * Drag-and-drop layout for any dashboard, any KPI, any module. The plant head's view, the operator's view and the corporate view come from the same designer * Multi-module aggregation puts quality, production and maintenance side by side on one screen, so the morning meeting stops being a tour of three different reports * Leadership-ready roll-ups: the same data model serves machine-level dashboards and corporate views. The CEO and the operator look at consistent numbers, just at different altitudes Built for the factory environment: * Self-updating slides at a configurable interval. No manual refresh, no stale numbers, no meeting that opens with "the data is from last week" * 24x7 shopfloor operation, designed for always-on TV display in noisy factory environments. The dashboard survives a network blip, a browser refresh and a Monday morning * 100+ languages with one-click translation, so the operator in Japan, the engineer in India and the plant head in Brazil see the same dashboard in their own language Because dashboards draw from the same live backbone as Zometric's SPC, production, maintenance and inspection modules, there is no manual report assembly and no stale data. The number on the wall is the number in the system. Browser-based with nothing to install, running on shopfloor TVs, desktops, tablets and phones. Free pilot configurable in 2 to 3 weeks with your real factory data.

Zometric Edge

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Zometric Edge answers the question at the start of every digitalization project: how fast can you turn an unconnected shopfloor into a live data source? It is the Industrial IoT layer that connects any machine, PLC, sensor or database to real-time manufacturing intelligence, including the 90 percent of factory equipment that generates no usable data today. Universal connectivity: * RS232 and RS485 serial devices, PLCs and DCS, SCADA systems, smart sensors, databases and historians, automated inspection systems, MES and ERP. If it has an interface, Zometric Edge speaks to it * Protocol support includes OPC UA, MQTT and Modbus * Legacy machines without any data output join through custom retrofit devices that convert electrical signals into digital data, enabling automated downtime, OEE and quality capture without replacing equipment Built like infrastructure, not a gadget: * Bidirectional data flow: the platform does not just read the shopfloor, it can actuate machines and close the loop when a control limit demands it * Architected against the ISA 95 Purdue Model, from Level 0 equipment through Level 4 enterprise, so enterprise IT recognises the diagram and signs the PO without a six-month review * Edge compute and buffering: process and filter data at the source, buffer through network outages, and push when the link is back. No silent data loss * Browser-based setup: configure connections from a tablet, with no thick-client install and no IT-led rollout to bottleneck deployment One Edge layer feeds every consumer of machine data: real-time SPC, production and OEE tracking, predictive maintenance, live dashboards, inspection and statistical analysis across the Zometric platform. Aligned with ISA 95, ISA 88, OPC UA, MQTT and Modbus standards. Free pilot configurable in 2 to 3 weeks on your real machines.

Zometric Maintenance Management

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Zometric Maintenance Management is a CMMS designed for manufacturing plants, not retrofitted to them. It answers the question that decides maintenance budgets: which asset is about to fail, and what will it cost if it does? Asset and work order foundations: * Asset hierarchy at any depth: Plant, Line, Cell, Machine, Sub-unit. Breakdowns, work orders and KPIs roll up correctly at every level, so the line manager sees the line and the plant head sees the plant * Work order engine with five categories: Corrective, Preventive, Predictive, Changeover and Turnaround, each with its own workflow, approvals and skill-based routing * PM scheduling with time-based, usage or cycle-count-based, and condition-based triggers, plus lead-time alerts so spares are staged and technicians are scheduled before the PM is due From reactive to predictive: * Predictive analytics ingest IoT sensor data via Zometric Edge, and the AI layer flags the failure mode before the breakdown. The shift to predictive maintenance becomes a deployment, not a multi-year project * Legacy machines join through retrofit edge devices, so automated downtime and condition tracking does not require replacing equipment. One customer cut downtime 40 percent this way Spares, costs and KPIs: * Centralised spare parts register with reorder alerts, consumption analytics and cost-per-asset tracking. Production scheduling locks against assets under maintenance * KPI dashboards for MTBF, MTTR, OEE contribution, PM compliance and cost per asset, with auto-generated shift and monthly MIS reports. The maintenance manager stops writing the report and starts reading it Breakdown root-cause analysis integrates with the platform's 8D problem-solving workflow, so recurring failures get engineered out, not just repaired. Aligned with ISO 55000, IATF 16949, 21 CFR Part 211 GMP, OSHA PSM and ISO 14224. Browser-based, works on technician phones and tablets. Free pilot configurable in 2 to 3 weeks with your real factory data.

Zometric SPC Software

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Zometric In-Process Quality & SPC gives quality teams real-time statistical process control across every product, every parameter and every plant. Catch process drift in seconds, not at end of shift: live control charts, instant alerts the moment a Nelson rule fires, and capability analysis recalculated on current data instead of stale reports. Live in 120+ plants worldwide, capturing over 8 million data points daily. Capture: meet your data where it already lives * Native PLC and IIoT integration with Allen-Bradley, Rockwell, Siemens, Beckhoff, Cognex, Delta and AutomationDirect, plus OPC-UA and MQTT * Operator-friendly manual entry on tablets with multi-sample subgroups, validation and offline sync * Bulk historical import, and edge connectors that retrofit legacy machines without replacing your automation stack Detect: the right signals, not the noise * Variable charts: I-MR, Xbar-R, Xbar-S, IMR-R/S, CUSUM, EWMA * Attribute charts: P, NP, U, C and Laney P with variable subgroup sizes * All eight Nelson rules, each toggleable per chart, with granular alert routing by product, process and parameter to the right supervisor, engineer or quality lead by email or SMS Act: capability and corrective action in a closed loop * Cp, Cpk, Pp, Ppk, Cpm, Z.bench, sigma within and overall, PPM expected vs observed, all validated against AIAG standards * Non-normal handling with Anderson-Darling, Shapiro-Wilk, Box-Cox and Johnson, plus the capability six-pack for new product introductions * Every violation logged with assigned cause, corrective action and follow-up Customer-measured outcomes include 18 to 30 percent scrap and rework reduction in year one, INR 1.62M annual give-away reclaimed on a single SKU, IATF audit-ready Cp/Cpk delivered in 30 days, and 38 percent faster defect detection on SMT lines. Compliance built in, not bolted on: 21 CFR Part 11 electronic records and signatures, IATF 16949 aligned, ISO 13485 ready, EU GMP and MHRA supported, AIAG SPC and MSA manuals. Deploy cloud, hybrid or on-premise, and migrate between models as operations evolve. Most cloud deployments are live within 30 days. Trusted by quality teams at Tata Autocomp Systems, CEAT, Tata Power Solar, Relaxo, Lucas TVS, Endurance Technologies and more.

Zometric Continuous Process Verification & APQR

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Zometric Continuous Process Verification & APQR is built for regulated pharmaceutical manufacturing, automating the two most resource-intensive compliance activities in the plant. The Annual Product Quality Review stops being a months-long sprint and becomes a living document the inspector can open today. Compliance becomes the byproduct of doing the work, not a separate deliverable. What changes versus the traditional APQR process: * Data collection: manual consolidation from paper and spreadsheets, arriving months after the campaign, is replaced by automated real-time streaming from instruments, MES and Zometric Edge. The data is in the dashboard before the batch is released * Analysis: offline statistical studies with limited visibility are replaced by live control charts and capability statistics. CPV becomes a state you observe, not a study you run once a quarter * Reporting: the static, hard-to-verify annual PDF becomes a dynamic living document that updates as the process runs, always traceable to the underlying records * Storage: high-cost paper archives kept for years are replaced by searchable digital storage. Retrieval that took weeks now takes seconds, with full lineage to the source measurement Compliance architecture: * 21 CFR Part 11 electronic signatures on every action * Complete user-action audit trail per record * Anytime inspection readiness: when the inspector arrives, you do not prepare, you open the dashboard. Every record, every signature, every trend is one click away Built for the standards your regulators already require: US FDA 21 CFR Part 11, ICH Q10, US FDA cGMP, ISO 13485 and 21 CFR 820, extending coverage to medical device quality systems. Analysis runs on the same validated Statistical AI engine behind the Zometric platform, including ICH Q1E compliant stability studies. Deployed at pharmaceutical manufacturers including Brawn Laboratories, Extrovis and Sekhmet Pharmaventures group companies. Browser-based, deployable cloud, hybrid or on-premise. Free pilot configurable in 2 to 3 weeks with your real data.

Zometric Inventory

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Zometric Inventory Management answers the question every stores audit begins with: do you know exactly what's in every store, in every unit, right now? It gives manufacturers real-time inventory visibility and control across all stores in the plant, where nothing moves without a record. Every movement, tracked: * Multi-store records: live stock levels across raw material, packaging, shopfloor, finished goods and vendor-managed inventory. One source of truth for every store * Goods receipt (GRN) with batch and lot numbers, expiry dates, serial numbers and supplier references. The receipt becomes the first link in the traceability chain * Material request and issue: operators raise formal requests, store managers release with batch selection, and every issue is attributable to a person, a job and a batch * Returns to store, inter-store transfers and scrap or write-off workflows, each with senior sign-off where required Built for regulated and batch industries: * Batch, lot and expiry tracking with FIFO or FEFO batch suggestion on issue, and pre-expiry alerts at 90, 60 and 30 days, essential for pharma, food and chemicals * Serial number tracking with a full state lifecycle from In Stock to Issued, Returned or Scrapped, forming the join key for end-to-end traceability * Multi unit of measure: purchased in drums, tracked in litres, issued in millilitres, with configurable conversion factors per item and no manual arithmetic for the stores team Control and accuracy: * Replenishment management with near real-time reorder-point alerts, and on-hand versus in-transit clearly demarcated so stock is never double-counted * Physical stock counts with items locked during counting, book quantity hidden during entry to prevent anchoring, and variances requiring senior sign-off before adjustment Supports IATF 16949, 21 CFR Part 11 and ISO 9001 traceability requirements across automotive, pharma and medical devices, chemicals, food and beverage, electronics and energy. Ties into production and inspection on the shared Zometric backbone, so material consumption reconciles against actual production and inspection status gates what can be issued. Browser-based on stores-floor tablets and handhelds. Free pilot configurable in 2 to 3 weeks.