Production, OEE & Quality — the physical explanation behind the number
PLC and MES data tell you the KPI moved. Fogsphere correlates the physical events on the line — accumulations, interventions, operator absence — that explain why.
Safety
Worker intervention on running lines and the conditions around each stoppage.
Security
Product, label and packaging verification, with traceability back to the clip.
Operational Intelligence
Line state, starved and blocked minutes, changeover duration and bottleneck location.
How Fogsphere sees a production line
A live performance layer on top of the cameras already covering your lines, changeovers and packing halls.
Key use cases
What Fogsphere explains behind every OEE movement, from line state to packaging defect.
Worker intervention
Maintenance and jam clearing
Manual interventions
Product and label verification
Packaging and pallet defects
Traceability and recall
Line state detection
Flow and congestion
Changeover and cleaning downtime
Running, starved, blocked or stopped — and for how long
Line state detection
Line running or stopped, micro-stoppages, starved line, blocked line and product accumulation, timestamped per asset.
Flow and congestion
Product flow and throughput, conveyor congestion, queue buildup between processes and packaging bottlenecks.
Changeover and cleaning downtime
Changeover and setup duration, cleaning downtime and unplanned downtime, separated rather than pooled.
Worker intervention
Worker intervention frequency and duration, idle stations, worker presence at required stations and line staffing.
Reject and palletising
Reject accumulation and palletising throughput, so the end of the line stops being a blind spot.
Bottleneck location
Where the constraint actually sits this week, correlated with PLC and MES data rather than inferred from output alone.
A visual intelligence layer for OEE
Availability and performance
Production speed, cycle time, micro-stop frequency, mean stop duration and equipment idle time.
Starved and blocked minutes
Starved-line time and blocked-line time separated, so upstream and downstream causes are distinguishable.
Manual interventions
Manual intervention count, operator response time and labour utilisation across the shift.
Downtime reason evidence
Every stop carries the clip that shows what happened, so downtime reason codes stop being guesswork.
Product, label and packaging verification
Product and label verification
Incorrect product, incorrect packaging, missing labels, label positioning, cap presence and closure integrity.
Fill and reject verification
Fill-level anomalies and reject verification, confirming the reject actually left the line.
Packaging and pallet defects
Damaged packaging, crushed cartons, incorrect case configuration, missing components and incorrect pallet patterns.
Defect trends
Product colour, shape, size and orientation anomalies aggregated into defect trends by line, shift and SKU.
Specialised imaging
Specialised industrial cameras take this well beyond ordinary surveillance where the defect class demands it.
Traceability and recall
Batch, line, time, operator, material, pallet and vehicle correlated with video, narrowing recall scope and shortening CAPA investigation.
Application clusters behind this focus area
Ready to explain every OEE movement with the events behind it?
Across the food and beverage estate
Explore our food and beverage focus areas.
Hairnet, glove and handwash compliance, hygienic zoning, HACCP verification and sanitation evidence.
PPE, wet floors, machine guarding, pinch points, emergency egress and e-mustering.
Line status, micro-stoppages, changeover, cycle time and packaging defect trends.
Cold-room doors, product dwell outside refrigeration, forklift flow, docks and pallets.
Critical-area access, tamper indicators, perimeter, contractors and visitor accountability.