A large SKU mix and shifting campaigns
The schedule changes every week, and every change costs another setup.
Animal health manufacturing · GMP
Every hour a machine stands still is volume that never comes back.
From weighing to filling, Cogtive shows where time is lost, shortens the setups of a large mix and releases the capacity you already have installed.
A specialist replies within 2 business hours.
- +29%
- OEE at Ourofino, with 85 pieces of equipment connected
- −69.7%
- equipment wait time at JA Saúde Animal, in 60 days
- ~600 h
- per year saved by the team and operators at Ourofino
Animal health manufacturers that run on Cogtive
Where capacity hides
Campaigns change every week. The line has to keep up.
A large mix of SKUs, long setups and campaigns accepted on gut feeling. The plant looks busy, and the volume still falls short.
Setups of six to seven hours
Cleaning, adjustment and checks done differently on every shift, with no standard to improve on.
Waiting time nobody records
Machines waiting for material or for the next order disappear from the entries and only show up at month-end.
Campaigns accepted without knowing the capacity
The volume is committed before anyone knows whether the line can deliver it.
How Cogtive solves it
From weighing to filling, one cockpit.
Each pain maps to a pillar of the cockpit, on top of a complete OEE foundation.
SetupSolves 01
Shorter setups, sustained with data
Guided Setup on the tablet turns SMED into a standard every shift follows, with phases, checklists and the time per phase recorded automatically.
FlowSolves 02
Every order in sight
Flow View shows every order from weighing to filling, the queue at each stage and the bottleneck of the shift.
CapacitySolves 03
Campaigns with known capacity
Simulate campaigns and SKU mix and see the OEE each scenario requires, before you commit the volume.
OEESolves 04
Automatic data, machine by machine
OEE collected through IoT or the tablet app on each piece of equipment, with downtime Pareto, MTBF and MTTR.
OEE tools give you a speedometer. Cogtive gives you the entire cockpit. See the whole platform →
Shop-floor compliance · GMP
The same discipline as human pharma.
Cleanings, batch changeovers and maintenance are recorded on the tablet, signed by PIN and sealed once saved, with versioned templates, an audit trail and data integrity. A validatable solution.
- Electronic logbookCleanings, changeovers and maintenance, signed by PIN and sealed once saved.
- Audit trailWho changed what, the previous value, the new one and when.
- Versioned templatesWhat each record requires, who fills it in and who verifies it.
- QR code validationFor critical events, such as opening a corrective work order.
Results
Proven in animal health plants.
+29%
OEE
With 85 pieces of equipment connected through IoT and the tablet app, and the production flow followed in Flow View, Ourofino raised its OEE by 29% and saved about 600 hours a year.
“Through the virtualization and real-time tracking of the entire process, Cogtive improved our OEE by 29%.”
−69.7%
equipment wait time
With real-time OEE across two plants, JA Saúde Animal cut equipment wait time by 69.7% in 60 days, standardized setups with SMED and raised equipment performance by 25%.
- 100+
- manufacturers
- +30%
- production capacity
- 12×
- return on investment
- NPS +85
- customer satisfaction
How we start
We start with what creates value now.
CAPTA diagnostic
A short questionnaire with your team shows where the biggest loss is and what to connect first.
The cockpit live
Data from IoT, sensors or the tablet. OEE, stops and losses in real time as soon as the first line is connected.
Routine and evolution
Our Customer Success team of Operational Excellence professionals runs the routine with yours, then expands where it makes sense.
We don’t sell what you won’t use yet. About the CAPTA method →
FAQ
Before you ask.
We already measure OEE. What changes?
OEE shows how efficient a machine was. Cogtive also shows where each order waits, how long each setup phase takes and whether the next campaign fits, so the team knows what to do next.
Can we connect older machines?
Yes. Data comes in the way the plant allows: IoT and sensors where possible, entries on the tablet where not. At Ourofino, 12 pieces of equipment were connected through IoT and 73 through the tablet app.
Does Cogtive replace our MES or ERP?
No. Cogtive works alongside them. The MES records execution and the ERP plans; Cogtive manages flow, pace, setup and capacity on top of what actually happens on the shop floor.
Do we need to start with every line?
No. A short CAPTA questionnaire shows where your operation stands, and we start with what creates value now. We don’t sell what you won’t use yet.
Book your demo
Find out how much installed capacity is standing still.
See the cockpit running on a line like yours. A specialist replies within 2 business hours.
Biel/Bienne, SwitzerlandSão Paulo, Brazil