Book a demoEvery hour of downtime at your chemical plant is costly. See your operation's real OEE, from reactor to filling, in real time, and recover production capacity without new investment.
Separation, fractionation, tanks, color matching, quality, filling. When a stage stalls, Cogtive shows you where, why — and how much it's costing you.
In the chemical industry, every unplanned stoppage directly impacts the cost per batch. Cogtive captures every event in real time — setups, color changes, maintenance, and micro-stops — and automatically calculates the line's OEE.
With Timeline, you see 24 hours of history for each piece of equipment. With automatic Pareto, your team acts on the root cause the same day.
On a paint line running 120 buckets/hour, a 12-point OEE gain represents nearly 6,000 extra buckets per month — more than R$107,000 in recovered production capacity.
Chemical production goes through many stages. When one stalls, the impact ripples through all the following ones — but it isn't always visible. Flow View shows in real time where each order is, which stage has a growing queue, and where the main bottleneck is.
Reposition priority orders with a single click and avoid discovering delivery delays only at the end of the shift.
In the paint and chemical industry, every product changeover involves tank cleaning, viscosity adjustment, and color validation. Smart Setup standardizes this process with a step-by-step digital guide right on the operator's tablet.
With the Ramp-Up report, you track whether the equipment returned to standard speed after the changeover — and identify whether the setup was done correctly before the problem shows up in the final product.
Production Management System
Hover over this section to pause the video and watch OEE drop
The hidden capacity in your chemical plant could be your operation's next big leap. Cogtive uncovers what was previously hidden on the shop floor — and turns that visibility into real financial results.
On a line running 120 buckets/hour, a 12-point OEE gain represents more than R$107,000 in recovered capacity per month. The gain from just 15 days already pays for a full year of the project — using your own operation's data.
Reactors, tanks, and mixers work in batches — not by piece. Cogtive calculates OEE by cycle time, with no need for unit counting, eliminating distortions in availability and performance metrics.
Flow View identifies in real time which stage has a growing queue — separation, tanks, quality, or filling. Your team acts before the delay reaches the customer, not after.
Every color or formula change in the chemical industry involves cleaning, adjustment, and validation. Smart Setup standardizes this process with a digital checklist and monitors ramp-up after the changeover — confirming the equipment returned to expected performance.
Every log is linked to the user, the equipment, and the exact timestamp. The audit trail ensures traceability of every action — essential for regulated processes, internal audits, and the sector's quality requirements.
Operators log directly on the tablet, or IoT sensors collect data automatically. Metrics update in real time, with no need to wait until the end of the shift to know what happened in production.
in savings generated for clients
increase in production capacity
reduction in lead time
return on investment
increase in equipment availability
payback per industrial unit
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In the manufacturing industry, continuous performance improvement is crucial to achieve operational efficiency and competitiveness. Moreover, it is important to consider that there are specific metrics that can guide this process. One essential metric for evaluating production efficiency is OEE, which stands for Overall Equipment Effectiveness. This metric measures resource utilization and production quality. In […]
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Industry 4.0 is characterized by the use of advanced technologies and connectivity to increase efficiency, productivity, and quality in manufacturing. In this context, measuring indicators is essential to identify areas for improvement and make data-driven decisions. Additionally, one of the most important indicators for Industry 4.0 is OEE, which stands for Overall Equipment Effectiveness. What […]
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Although dealing with idle capacity is common in the industrial environment, here we are going to talk about hidden capacity, which involves a comprehensive analysis of lead times and production bottlenecks throughout the factory, and not just individual equipment. This approach allows for the identification of various improvement opportunities that go beyond simply maximizing equipment […]