Batches waiting between stages
Waiting for a machine, for material or for QC release, and nobody sees the queue until lead time has already grown.
Pharmaceutical manufacturing · GMP
Release more batches with the plant you already have.
Cogtive shows where every batch waits between stages, controls holding time and standardizes every changeover, with records ready for the inspection.
A specialist replies within 2 business hours.
- −46%
- lead time at Apsen, postponing a new plant by more than 4 years
- 18.5% → 41.9%
- OEE at Axantia in 11 months, without buying new machines
- −47%
- lead time at Brasterápica
Pharmaceutical manufacturers that run on Cogtive
The real bottleneck
In pharma, the biggest loss is not at the machine. It is between the stages.
OEE tells you how a machine performed. It does not show the batch waiting for QC release, the holding time about to expire or the changeover that takes a different time on every shift.
Holding time on a spreadsheet
Intermediate products with expiry windows, tracked by hand or by memory. One missed limit means rework or a rejected batch.
Changeovers that depend on the shift
Batch changeover and line clearance run differently with each operator, and the ramp-up after the changeover is never measured.
Paper logbooks before an inspection
Cleanings, changeovers and maintenance on paper, with evidence that takes days to gather when the auditor asks.
How Cogtive solves it
One cockpit, from dispensing to QC release.
Each pain maps to a pillar of the cockpit, on top of a complete OEE foundation.
FlowSolves 01
Every batch on its route
Flow View shows where each batch is and how long it has been waiting, with lead time per stage, FIFO by expiry and an alert before holding time runs out.
SetupSolves 02
Changeovers to one standard
Guided Setup on the tablet takes every shift through the same phases and checklists, records the time per phase and measures the ramp-up after each changeover.
ComplianceSolves 03
Records ready for the inspection
The electronic logbook records cleanings, changeovers and maintenance, signed by PIN and sealed once saved, with versioned templates and an audit trail.
OEESolves 04
OEE by batch cycle
OEE calculated by batch cycle time, without distorting availability, plus downtime Pareto, MTBF and MTTR fed by IoT or the tablet.
OEE tools give you a speedometer. Cogtive gives you the entire cockpit. See the whole platform →
Shop-floor compliance · GMP
Made for the regulated shop floor.
The events regulators such as the FDA and ANVISA require you to document are recorded on the platform, with an audit trail and data integrity. The logbook is a validatable solution, and your Quality team is involved from the start.
- 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 pharmaceutical plants.
−46%
lead time
With 51 pieces of equipment connected and every batch visible in Flow View, Apsen cut its lead time by 46% and postponed the investment in a new plant by more than four years.
“With Cogtive, instead of looking in the rearview mirror at something that already happened, you act on it instantly, in real time. Today a stoppage might last, say, two hours. Before, without visibility, without being online, without alerts, that same stoppage could last four or even five hours. So we definitely gained production capacity.”
+126%
OEE in 11 months
At its plant in Jordan, Axantia replaced spreadsheets with real-time shop-floor data and Flow View, raising OEE from 18.5% to 41.9% in 11 months without buying new machines.
−47%
lead time
Real-time data from 16 machines, daily Gemba walks and pull production on 60% of the plant took Brasterápica's lead time from 12–15 days to 8 days while operations doubled.
- 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.
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.
Is the electronic logbook validated?
The logbook is a validatable solution. Validation happens in your environment, with your Quality team, whom we involve from the start of the implementation.
Can Cogtive control holding time and expiry windows?
Yes. Flow View tracks how long each intermediate product waits between stages against its limit, and alerts the team before the limit is exceeded.
How does data get into Cogtive?
The way your plant allows: IoT and sensors on the machines, cameras with AI Vision and entries on the tablet. Micro-stops are captured too, and older machines can start on the tablet.
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 many more batches your plant can release.
See the cockpit running on a line like yours. A specialist replies within 2 business hours.
Biel/Bienne, SwitzerlandSão Paulo, Brazil