Xcope agentTrue cost per order
Machine hours, changeovers, scrap and energy added to each order and compared with its costing.
Put AI to workin manufacturing.
The MES and ERP you already have start explaining every stoppage and the true cost of every order.
The challenge
Do you know what the last order to leave the plant actually cost you?
The MES logs stoppages with its own codes and the maintenance software logs interventions with different ones. Hours and material use sit in the ERP, so the cost of each order ends up as an estimate and no stoppage is ever linked to the one before.
- 01
Stoppages with a vague cause
When the line stops, the operator logs what they can and gets it running again. Many stoppages end up as ‘other’, and the pattern that comes before the next breakdown never shows.
- 02
A plan redone by hand
A rush order means reshuffling the plan for several lines in a spreadsheet, with no view of the effect on deliveries already promised.
- 03
True cost by estimate
Costings use standard times. Changeovers, scrap and the energy used by each batch are left out, and a small order can lose money without anyone noticing.
Day to day
Questions that finally get answers
What did this customer's last order actually cost us?
Will this rush order fit into this week's plan?
Which machine is most likely to stop next?
Which line is seeing scrap go up?
Which critical spares are below minimum stock?
AI at work
Four answers drawn from the records your plant already keeps.
AI connects the MES, the ERP, the maintenance software and the sensors already in place to find the cause of each stoppage and redo the plan when a rush order comes in.
Rush orders
The plan redone with the new order in it, so you can give the customer a date the plant can meet.
OEE by line
Availability, performance and quality for each line, with the biggest source of loss flagged.
Goods‑in quality
Certificates and measurements for each batch of raw material checked against the specification before it reaches production.
Illustrative figures.
The data you already have, put to work
We connect to the systems you already have, without replacing them, and you decide which data each agent can read.
Works with what you already use
ERP, CRM, email and documents stay where they are, and nobody has to move to a new system.
Reads and cross‑checks your data
Brings together what is scattered today and finds what does not add up.
Proposes, you approve
Every sensitive action goes to whoever has the authority to approve it.
Acts and keeps a record
Works inside your team's systems and records where every decision came from.
The line with the most stoppages goes first.
We use the records that already exist for that line, and move on to the others once shift supervisors are using the answers day to day.
- 01
Assessment
We map the operation and the data and choose what reaches production first.
- Data sources mapped
- Opportunities assessed
- Scope and plan agreed
- 02
First system in production
We build in the tools you already use and put the system to work on real cases.
- MES and ERP connected
- Maintenance agent in production
- 03
A team that runs it
Your team takes the system over and we choose the next process together.
- Shift supervisors trained
- Next process chosen
Do we need to put sensors on the machines?
To begin with, hardly ever. The MES, the maintenance records and the machine alarms already say a great deal. Vibration or temperature sensors only go in where a breakdown costs more than the sensor.
Does it connect to our ERP and MES?
Yes, by whatever route each one allows: an API, read access to the database or scheduled exports, for example of works orders and downtime every hour. Nothing is written to the PLCs or the machine control systems.
How is the true cost of each order calculated?
We add up the machine and labour hours logged in the MES, the raw material used according to the ERP, the scrap recorded by quality and, where there are meters, the energy used by each line. The total is compared with the order's costing.
Does this replace the MES or the maintenance software?
No. It reads what those systems already record, and the work orders it proposes are created in the maintenance software your team already uses.
The next breakdown usually shows up first in the data you already have.
On the call we look at the stoppage log for one line and tell you what can be learned from it.
Book a callNot ready for a call yet. I would rather send a question.
Write down the question your operation cannot answer today. We will reply by email with how to get there.
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