PlantPulseProOEE + BCT optimization
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For batch-process manufacturing plants

See where every batch loses time.

Plant Pulse Pro tracks reactor activity, batch cycle time, production steps, cleaning, idle time and delay reasons so plant teams can calculate OEE accurately and improve daily production performance.

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Plant Pulse Pro does not replace ERP, DCS, historian or control systems. It gives production teams a structured layer for BCT, OEE and operational loss review.

Master standardsStructured entryOEE calculationReason analysis
Operational Problem

Manual batch review loses context before managers see the data.

Many plants still move production entries from batch cards into Excel before OEE or BCT review. By then, delay reason, step duration and reactor context can be inconsistent.

Batch cards are rewritten into spreadsheets after the event.
Step delays are discussed, but not always recorded with duration and reason.
Reactor-product standards are hard to keep consistent across teams.
Manual OEE and BCT workbooks are difficult to review daily.
Calculates OEE and Batch Cycle TimeShows current reactor and production statusCompares actual versus standard batch and step timesRecords step-level delay reasons and durationReplaces manual OEE and BCT Excel sheetsSupports reactor-product-specific standards
How It Works

From reactor-product standards to daily OEE review.

The workflow follows the current product: master setup, structured entry, reason capture, calculation and analysis.

01Plant Pulse Pro creates the isolated customer workspace and purchased structure limits.
02The customer configures company, site, plant, reactor, product and reactor-product standards.
03Define standard BCT and standard process-step times.
04Record batch and process-step start/end times.
05When a step exceeds standard, select one of the five configured delay reasons and assign duration.
06Automatically calculate BCT, deviations, OEE and operational losses.
07Analyze performance by reactor, product, process step and delay reason.
Real Product Interface

Built around the entry and review screens used in the workspace.

The public preview uses product concepts already present in the application: Master, Entry, Live, Analytics and Index.

Which Reactor Is Slow

Delay minutes by reactor

Demo

Product Delay Ranking

Delay contribution by product

Demo

Step Deviation Hotspots

Positive deviation by process step

Demo

Utilization Mix

Active, cleaning and idle time

Demo
Active25 hr 50 minCleaning3 hr 25 minIdle1 hr 30 min

Product-Reactor Heat Map

Delay and OEE for each operating combination

Demo
R-101Product A45 min delay · 79% OEE
R-102Product B35 min delay · 83% OEE
R-103Product C14 min delay · 88% OEE
R-104Product A22 min delay · 85% OEE
R-105Product D25 min delay · 82% OEE
R-106Product B8 min delay · 91% OEE

STD vs ACT by Step

Latest batch timing comparison

Demo

Historical Reactor OEE

Precalculated monthly A × P × Q values

6 months
Analytics From Demo Entries

See the operational loss behind each batch.

This preview is calculated from anonymized entries shaped like the reactor workbook: standard BCT, actual time, output, cleaning, idle time and delay reason. It is a product demonstration, not a customer result.

Reactor-wise active, idle, cleaning and delay review
Product-wise BCT and deviation comparison
Process-step standard versus actual timing
Delay reason frequency and duration analysis
Calculation modelOperational records become traceable metrics
A × P × Q
AAvailability(total time − idle − cleaning) / total time
PPerformanceStandard production rate compared with actual output
QQualityFirst-time-right quantity compared with total output

No customer result is shown on the public website. Inside the workspace, these calculations use only approved entries from the signed-in customer.

Industries

For batch-process plants where reactor time and step discipline matter.

Chemical manufacturingAgrochemical plantsPharmaceutical batch plantsPetrochemical operationsSpecialty chemicalsOther batch-process manufacturers
Security

Role and plant scope are checked for every workspace request.

Individual users are assigned customer, company, site, plant and role scope. Operator entries remain pending until a shift in-charge approves them. Direct ERP, DCS or historian integration is not claimed on this page.

Onboarding

Start with one reactor, one plant or a complete site.

A team can begin by configuring products, reactors, standards and reason lists, then expand as more plants, sites and customer workspaces are added.

1. Prepare master data2. Train structured entry3. Review BCT and OEE daily
FAQ

Clear answers for plant teams.

Is Plant Pulse Pro an ERP or DCS replacement?

No. It is an operational OEE, BCT and delay tracing layer for production review. It does not replace ERP, DCS, historian or control systems.

Can the plant begin with manual structured batch entry?

Yes. The current product supports structured manual entry for reactor status, batch timing, step timing, cleaning, idle time and reasons.

Can standards differ by reactor and product?

Yes. Master data supports reactor-product-specific standards, BCT, step timings, capacity and active modes.

How are delays captured?

Actual step timing is compared with predefined standards. When delayed, users select a configured reason and enter delay duration.

Does it support multiple companies, sites and plants?

Yes. The master structure includes customer, company, site, plant and reactor levels.

Can a customer start with one reactor or one plant?

Yes. A plant can begin with a small master setup and expand as more reactors and products are added.

Is it suitable for small and medium manufacturers?

Yes. The workflow is designed for plants that need structured BCT and OEE review without starting from a large integration project.

Can managers see current production and reactor status?

Yes. The live view is based on the latest operational entries saved in the workspace.

Does it directly integrate with DCS or historians?

No direct DCS or historian integration is implemented in the current product.

Plant Demo

Review your current OEE and BCT workflow with Plant Pulse Pro.

Share how your team records batch timing today, and we can map the first reactor or plant setup.

Book a Plant Demo