Zednner Production Suite
Maximize production capacity utilization. Eliminate unplanned downtime, reduce setup times, and discover where your line's profit is leaking.
Instant calculation in the browser without installation • Audit reports to PDF • Support for voice announcement from the workshop
World-Class OEE ≥ 85%
Availability 90% • Performance 95% • Quality 99.9% according to the world's best standard.
Fast Control OEE Calculator
See how the product of three basic pillars affects the overall efficiency of your plant: OEE = A × P × Q.
Stable process. Focus on eliminating micro-flags to move above 85%.
Open Full OEE & TPM Studio with DowntimeProduction Suite modules
A comprehensive package of tools for discrete production, automotive molding plants, injection molding plants and assembly operations.
OEE & TPM Studio
Complete OEE calculation according to SEMI E10 and Nakajima TPM. Automatic breakdown of 6 large losses, Pareto fault analysis and export to PDF shift report.
- Indicators A, P, Q and total OEE
- Waterfall Breakdown 6 Big Losses
- Reliability of maintenance (MTBF, MTTR, A_tech)
- Pareto Downtime Cause Analysis (80/20)
- Import of shifts and downtime from Excel (.xlsx, CSV)
8D Report & Kaizen Studio
Systematic solution of root causes of failures and rejects. Directly connected to OEE shifts, 5-Whys iterative analysis, 6M Ishikawa fishbone diagram and visual lean production.
- Workshop Kaizen Board (Kanban) for Touch TV
- Photo documentation of BEFORE/AFTER and SQDCM objectives
- Executive Dashboard of Savings & ROI in CZK
- Normative 8D Report according to VDA and AIAG + 5x Why
- Official A4 printing protocols (Kaizen & 8D)
Shopfloor KPI & Line Balancing
Line clock analysis (Clock time vs. Cycle time), Yamazumi diagrams for balancing VA/BVA/NVA operations, bottleneck detection and What-If simulator.
- Interactive Yamazumi Diagram and Clock Time
- Bottlenecks and LBE % detection
- What-If Clock Optimization Simulator
- By-Hour Production Tracker and SQDCM
- Large Format TV Andon Kiosk and A4 Printing
SMED Studio (Reconstructions)
Shigeo Shingo (Single-Minute Exchange of Die) methodology to reduce downtime of line and press conversions under 10 minutes and direct transfer to Kaizen.
- Decomposition: Internal vs Outer Time
- Comparative Gantt & Waterfall Before / After
- Finish Single-Minute (<10 min)
- Financial ROI calculator (savings in CZK/year)
- 1-click to Kaizen and A4 PDF audit report
Digital Twin Production Line
Discrete dynamic simulation of production flow in real time. It models station behavior, buffer capacity, blocking/starvation propagation, and automatically detects bottlenecks according to Goldratt's Theory of Constraints (TOC).
- 2D Workshop Layout & Material Flow: Flexible spatial arrangement of stations in the workshop (lines on top of each other, kitting zones, printers, belt and roller conveyors and parallel branching).
- Dynamic Buffers (Buffers min/max): real physics of material flow – automatic stopping of the previous station at full buffer (blocking) and starvation of the follow-up station at empty buffer (starvation).
- Predictive Maintenance (PdM) & Degradation: real-time monitoring of component wear, predicting accidents and planning for preventive shutdowns before unplanned downtime occurs.
- AI Lean & OEE Engineering Auditor: direct simulation evaluation via OpenAI with secure prompt, bottleneck identification (TOC), and CAPA action plan generation according to IATF 16949 / Lean Six Sigma.
- Custom Line Configurator [PRO]: model any race (up to 25+ stations) with a quick jump of the entire 8h shift in 0.2 s.
- Digital Birth Certificate & Run@Rate Report: 100% traceability of process parameters and A4 audit printing for customer inspections.
Connect the Production Suite to your production MES / ERP system
Automate the forwarding of downtime, OEE data, and 8D reports. REST API with OpenAPI v3 specification (Swagger), cURL, C# and Python SDK.
Why switch from Excel and paper reports to Production Suite?
Excel on the shop floor often leads to formula loss, inconsistent downtime definitions, and lack of auditability.
| Criterion | Common practice (Excel and paper) | Zednner Production Suite |
|---|---|---|
| Speed of entering downtime | Lengthy writing on paper and manual transcription at the end of the shift | Instant input via tablet directly at the line or voice recording |
| Analysis of 6 big losses | Complex macros and tables, common errors in formulas | One-click automatic decay according to SEMI E10 and Nakajima TPM |
| Resolution of non-conformities (8D & Ishikawa) | Isolated files on a network drive, confusing versions | Central linking with photo documentation and audit PDF export |
| Data security and access | Risk of accidental overwriting or deletion of a file | Audited system with the possibility of On-Premise installation on the company server |
Ready to maximize the productivity of your production?
Try OEE Studio and Workshop Kaizen Board without registration directly in your browser.
What's new and what we're planning for Production Suite
We are constantly pushing the possibilities of our solutions. View recently deployed features, vote for upcoming modules or design your own extensions.
Deployed new features in live operation
Features and tools that are already fully available in the current version.
OEE & TPM Studio
Průmyslový výpočet Dostupnosti, Výkonu a Kvality dle norem SEMI E10 a Nakajima TPM.
Waterfall 6 velkých ztrát
Okamžitá dekompozice prostojů linky (poruchy, seřizování, mikrostoppy, snížená rychlost, zmetky).
Ukazatele údržby MTBF & MTTR
Automatické sledování střední doby mezi poruchami a doby opravy vázané na směny.
SMED Studio & Zkracování přestaveb
Digitální stopky a workflow pro oddělení a převod interních činností na externí.
8D Report & Kaizen Board
Řešení neshod D1–D8 dle IATF 16949, 5 Why a 6M Ishikawa s generováním oficiálního zákaznického PDF.
Chystané funkce – rozhodněte o prioritách
Kliknutím na tlačítko Mám zájem pomůžete upřednostnit vývoj a získáte přednostní přístup k beta verzi.
Přímé IoT vyčítání z PLC (OPC-UA / MQTT / Siemens S7)
Automatický záchyt mikrostoppů (< 3 min) a taktů bez manuálního zadávání operátorem.
Prediktivní AI údržba (Vibrační a teplotní telemetrie)
Včasná detekce blížícího se zadření ložisek vřeten s automatickým servisním tiketem.
Mobilní autonomní TPM checklist s OCR fotodokumentací
Povinné ověření stavu stroje na začátku směny operátorem přes tablet nebo telefon.
Design a custom feature
Do you have a specific process or requirement that is missing from the list? Write to us and we will design it tailored to your production.