Operations
Book a feasibility study

Turn the cameras on your floor into a live record of how work gets done

Agnify watches the cameras you already have, plus a camera over any station that needs one. It measures machine uptime and downtime, cycle time by station, missed assembly steps and material moving through the plant, by shift, line and site, without a clipboard.

Book a free feasibility study See what it measures
Works with the cameras you already have Activity by station and role, never by identity Dashboards, alerts and an API that sit alongside your MES
Generated illustration · example boxes
A large production floor seen from a corner camera, with assembly lines, workers at stations and a forklift in the main aisle
Line 2 · running
Forklift · WIP to line 3
Station 7 · staffed
Cart waiting 12 min
CAM-04 · Hall B · assembly lines 1 to 4Example site

Downtime is expensive, a few OEE points add millions in capacity, and half of smaller plants still run on paper

$1.4T

A year lost to unplanned downtime by the world's 500 largest companies, about 11% of their revenue, by Siemens' estimate1

Siemens, True Cost of Downtime 2024
$150K

What one hour of unplanned downtime can cost a small or mid-sized manufacturer, at the top end1

Siemens, True Cost of Downtime 2024
+10%

More good output from the same line and planned hours when OEE rises 6 points, from a typical 60% to 66%. On a $50M line, that's up to $5M a year of added capacity2

Illustrative; assumes the line is the constraint
54%

Of small and mid-sized plants still track production on paper or spreadsheets. Agnify records that data from your cameras and can feed it into your MES or spreadsheets3

IoT Analytics, MES Market Report, 2025

Most of what happens on the floor never becomes data

PLCs see the machines that are wired up. Your MES sees the scans. Everything in between is written down at the end of the shift, if at all. Cameras already see all of it.

Stops without a reason

Downtime is logged from memory, and manual logs are "often highly inaccurate." Short stops disappear from the record altogether.4

01 · Equipment →

Manual steps without a sensor

Nothing records the bolt, the connector or the label that a person fits by hand, until a unit fails later.

02 · Process →

Labor without a picture

The staffing plan says one thing. The floor says another, and walking, waiting and searching never show up anywhere.

03 · People →

Material between scans

A pallet is scanned in and scanned out. How long it waited, and where, stays invisible.

04 · Material →
01 · EQUIPMENT

Uptime and downtime for every machine a camera can see

Running, idle or down, read from the stack light, the door, the spindle or the parts coming out. That works on older machines with no data connection too. Every stop gets a start, an end, a duration and the clip, so the reason comes from a look at the clip, not a guess.

Generated illustration · example boxes
Five identical CNC machining centers in a row; machine 3 has a red stack light and its door open
CAM-11 · Machining cell A10:42

Boxes, states and timelines are an illustration with example data, not model output.

Machining cell A · shift 1Machine states since 06:00 · example data
1 down
Cell uptime this shift84%
RunningIdleDown
    Downtime with the clipPlanned or unplanned, changeover, waiting on material, waiting on maintenance. The reason is picked from the footage.
    The short stops tooTwo-minute stops that nobody writes down, counted and totaled by machine and shift.
    Response timeFrom the moment a machine stops to the moment a technician arrives, and on to the restart.
    02 · PROCESS

    Every stage of the process, and every step at each station

    A camera over each station confirms the step happened before the unit moves on: part present, fastened, guard fitted, label on. Missed and out-of-order steps are flagged at the station, not at final inspection. The same cameras time each stage, so you can see where the line is really constrained.

    Generated illustration · example boxes
    Station 4 on a generator assembly line: an operator fits the control panel onto a generator set on a conveyor pallet, next to a rack of parts bins
    CAM-S4 · Generator line · station 4, panel and wiring14:07
    Unit GS-2291 · station 4Panel and wiring · standard work, 5 steps · example data
    Hold at station

      Cycle time by station against takt

      Median minutes per unit · generator line · last 20 units · example data

      Station 3 is the constraint: over takt on 14 of the last 20 units. Hover a bar for details.

      Overhead view of a generator assembly line with five stations, each unit at a later stage of assemblyGenerated illustration
      Caught at the stationIn a Sandia study, trained inspectors caught 85% of defective parts.5 Checking each step as it happens stops the misses from reaching final inspection.
      Stage timingTime in each stage for every unit, from frame load to pack-out, with the stations that hold the line up.
      Traceable unitsEach unit's steps, times and clips kept together, ready for a customer query or a warranty claim.
      03 · PEOPLE

      Where the hours go, by station and role

      Shows which stations are staffed or empty, time spent working versus waiting, headcount by area against plan, and the walking and searching that never makes it into a time study. With up to 1.9 million US manufacturing jobs at risk of going unfilled by 2033, every staffed hour counts.6 It's built to help teams balance work, not to watch individuals.

      Generated illustration · example boxes
      Overhead view of a generator assembly line with operators at five stations
      S1 · working
      S2 · working
      S3 · waiting on part
      S4 · working
      S5 · inspecting
      CAM-L1 · Generator line · overheadExample boxes

      Time at each station, shift 1

      Share of staffed time · example data

      WorkingWaitingWalking or searching

      Activity, not identity. Agnify reports by station, zone, role and shift. It uses no facial recognition, whole-person blur can be switched on for video outputs, and retention is set to the shortest period the purpose needs. We help you brief your teams and, where one exists, the works council or union before anything goes live.

      04 · MATERIAL

      Material through the facility, from dock to dock

      Follow pallets, carts and WIP from receiving through production to shipping. You'll see where work in progress piles up, how long it waits between stations, which dock doors are busy and how forklifts spend their time. A plant's flow map, drawn from what really happened.

      Generated illustration · example flow
      Isometric cutaway of a manufacturing facility with receiving, storage, production lines, staging and shipping areas
      Receiving · 2 trucks at the door
      Queue at test · 42 min avg
      Shipping · trailer loading

      Where a pallet's time goes

      Receiving to shipping, median, last 7 days · example data

      Value-added time is the small slice. The rest is waiting, and waiting is where the space and cash go.

      WIP and dwellCounts in each staging square and the time since each pallet arrived, with queues flagged before the next station starves.
      Docks and trailersDoor occupancy, trailer dwell and loading time, set against the ship schedule.
      Forklifts and tuggersLoaded versus empty travel, idle time and the busiest routes.
      05 · OEE AND IMPROVEMENT

      OEE from what really happened, with the clip behind every loss

      Availability comes from real stop times, performance from counted cycles and quality from rejects seen at the station. OEE per line and shift, broken into the losses your daily meeting can act on, and questions answered in plain English: "When did line 3 stop yesterday, and why?" Manufacturers investing in smart manufacturing report 10–15% of capacity unlocked.7

      Line 2 · shift 1 · where the 7.5 planned hours went

      Example data

        80%Availability
        85%Performance
        96%Quality
        65%OEE
        A supervisor and operators at a start-of-shift huddle around a tier board on the factory floorGenerated illustration

        What a few points of OEE are worth on your line

        With the same planned hours and product mix, good output rises in proportion to OEE. Put in your own numbers.

        Illustrative arithmetic, not a measured or guaranteed result. Assumes this line is the plant's constraint, with the same product mix, ideal cycle time and planned hours. Added capacity becomes revenue only where there's demand; otherwise it's the same volume in fewer hours.

        +10%More good output from the same planned hours
        $5.0MAdded capacity a year, where there's demand
        545 hPlanned hours a year freed up if you make the same volume instead

        The same capabilities on any floor

        Agnify is built around what operations teams measure, not around one industry. Here's how it reads on four kinds of floor.

        A worker fastening engine mounts on a generator set on a roller conveyorGenerated illustration

        Assembly lines

        • Step checks at each station
        • Cycle time against takt
        • Stations staffed or empty
        • Rework loop and first-pass yield
        A line of stamping presses; one is stopped with a red stack light and a technician insideGenerated illustration

        Machining and fabrication

        • Machine running, idle or down
        • Changeover time
        • Maintenance response
        • Parts out per hour
        A food packaging line with trays moving into a case packer and workers in white coatsGenerated illustration

        Food, beverage and process

        • Line stops, jams and starved fillers
        • Batch and stage timing
        • Changeover and sanitation time
        • Cases and pallets counted
        Shipping dock with trailers at open doors and pallets staged in marked lanesGenerated illustration

        Warehouses and docks

        • Door occupancy and trailer dwell
        • Staging lanes filled and cleared
        • Forklift utilization
        • Pallets in and out

        51 applications on the same cameras

        The three most requested in each group first. Each is a rule on a camera view, and a feasibility study shows which work on yours.

        Equipment and uptime

        A technician repairing a stopped conveyor motor while a supervisor watchesGenerated illustration
        Machine stateRunning, idle or down from stack lights, doors and motion, on any machine
        Downtime with the clipStart, end, duration and a reason picked from the footage
        Changeover timeFrom the last good part to the first good part, every time
        AlsoShort stopsPlanned vs unplanned stopsMaintenance response timeAndon and stack-light logConveyor jams and blockagesStarved and blocked machinesCrane and hoist useAnalog gauge reading

        Process and assembly

        An operator fitting a control panel on a generator set at station 4Generated illustration
        Step verificationEach step at each station confirmed before the unit moves on
        Cycle time by stationPer unit and per step, against takt
        Bottleneck finderThe station that sets the pace, and how often it's over takt
        AlsoOut-of-sequence stepsUnits in and out per stationKit completenessStandard work adherenceRework loopFirst-pass yieldBatch and stage timingLine start-up and shift ramp

        People and labor

        Workers at assembly stations seen from a mezzanineGenerated illustration
        Station staffed or emptyCoverage by station and shift, including breaks
        Working vs waitingWhere people wait on parts, machines or instructions
        Headcount by areaPeople in each area against the staffing plan
        AlsoWalking and searching timeAutomatic spaghetti diagramsLine balance by laborShift handover gapsErgonomic strain (reach, bend, lift)Time studies from video

        Material and flow

        WIP staging area with pallets in floor-marked squares and a forkliftGenerated illustration
        WIP and dwellHow much is waiting between stations, and for how long
        Line-side stockEmpty bins and short kits flagged before the station stops
        Dock doors and trailersDoor occupancy, trailer dwell and load time
        AlsoPallet location by zoneForklift loaded vs empty travelTugger route timingStaging squares full or blockedFinished goods vs ship planFloor space useReceiving to put-away time

        Quality, safety and 5S

        An inspector checking a machined part under a ring lightGenerated illustration
        Visual checksParts present, oriented and labeled; visible defects at the station
        Reject countsUnits into the reject bin or rework bay, by station and shift
        Blocked aisles and exitsPallets and carts left where they shouldn't be
        AlsoLabel and packaging checksForeign objects on the lineForklift and pedestrian near missesRestricted zonesPPESpills on the floorTools returned, areas clear

        Start with the cameras you have and add one where a station needs it

        No rip and replace. Agnify connects to the feeds you already record, and a camera goes over each station where step checks matter.

        STEP 1

        Connect the views

        RTSP streams, your NVR or recorded footage. We map each camera to the lines, stations, zones and doors it sees.

        STEP 2

        We build it around your process

        Our engineers map your stations, steps, machine states and staging areas, then build and test the detection on your own footage before it goes live.

        STEP 3

        Run the floor on it

        Dashboards by line and shift, alerts with the frame to the people who own them, reports and events through the API.

        Cloud by default

        Nothing to host. Results arrive within minutes, which suits dashboards, shift reports and trend alerts.

        Real time on site

        For applications that need it, like holding a unit at a station or flagging a machine stop as it happens, Agnify runs on a server next to your cameras.

        Alongside your MES

        Events and counts go out through the API to your MES, BI or historian. Integrations are scoped per site.

        From your footage to a working result in two weeks

        A free feasibility study on one line, cell or dock, with an agreed end date and no commitment.

        Book a free feasibility study
        1. You send a few hours of footage, or camera accessPick the line, machine or station you'd most like to understand.
        2. We come back with a written resultWhat we can measure on your cameras, how reliably, and what the first dashboard would show.
        3. If it's useful, we scope a pilot togetherOne use case, live on your cameras, judged against criteria agreed up front.

        Questions operations teams ask first

        Do we need new cameras?

        For uptime, people and material flow, usually not: the cameras already covering the floor are often enough. For step checks at a manual station we suggest a camera mounted over that station, because a ceiling camera across the hall can't see a bolt or a connector. The feasibility study checks angles and resolution on the views you care about.

        We already have an MES and machine data. Why cameras?

        Machine signals tell you a machine stopped. The camera shows why, and covers what isn't wired: manual stations, older machines, material between scans and people. Agnify sends its events and counts to the systems you already use, so the camera fills the gaps rather than duplicating what you have.

        How do you handle privacy and our workforce?

        Reports are by station, zone, role and shift, not by named person. There's no facial recognition, whole-person blur can be enabled for video outputs, and retention is kept short. We help you explain the purpose to your teams and consult the works council or union where one exists.

        Can it work in real time?

        Yes, for the applications that need it. Step checks that hold a unit at the station, or alerts the moment a machine stops, run on a server on site next to the cameras. Dashboards and shift reports run in the cloud, where results arrive within minutes. Agnify signals and records; it isn't a certified safety system and doesn't replace machine guarding.

        How do we know it's accurate on our floor?

        We measure it on your footage. The feasibility study and the pilot report results against events your team checks by hand, before anything scales.

        What does it take from our IT team?

        Access to camera streams or an NVR export, and a network path out for cloud processing. Where an application needs real time, or video has to stay in the building, a server on site.

        Tell us about your operation

        Tell us about your floor and what you want to measure. We'll reply within one business day with next steps for a feasibility study.

        • Free, time bound and no commitment
        • Works from a few hours of footage or a camera stream
        • Or email info@agnify.ai