Flag the drift early
Real-Time Prediction forecasts quality every 30 seconds and flags drift while there is still time to correct it.
Real-Time Prediction →Keep the line running. Catch the drift before it becomes a stop.
Most stops and rework start as quality drift. ProcessMiner catches that drift early, so your line runs steadier, stops less often and recovers faster from grade changes and startups.
Read the transcript
Quality’s out of spec. Somewhere in hundreds of tags, one or two variables did it. Finding them by hand takes hours. Root Cause Analysis looks at every tag at once, drops the ones along for the ride, and ranks the top ten. One click opens the trend. PM Vector shows the move back. Your team spends the shift fixing it, not hunting for it.
Why lines stop
Stops don’t come out of nowhere. They come out of drift.
A stop is usually the last link in a chain that starts with quality drift nobody saw in time. Grade changes and startups are where off-spec piles up fastest.
$20K–$200K
Cost of one hour of unplanned downtime
Industry benchmark
~2×
Dewatering capacity
Same operating hours, wastewater dewatering pilot
$400K–$500K
Yearly value of a 0.1% quality gain
Average paper mill, industry benchmark
~2× is a ProcessMiner pilot result, measured against that plant’s own baseline. The dollar figures are industry benchmarks, not ProcessMiner results. Results vary; past performance is not a guarantee of future results. How we measure →
How it works
Catch the drift early and recover from a short list
Recover from a short list
Root Cause Analysis ranks the top 10 likely causes, so recovery starts from a short list.
Root Cause Analysis →Hold every crew to your best run
PM Vector shows each crew the setpoints from your best run, straight through grade changes.
PM Vector →Ask PM AI Agent “What happened on third shift?” It answers from your own process data, SOPs and run history.
By industry
What throughput means on your line
Pulp & paper
Steadier grade changes and turn-ups. Fiber is ~50% of production cost (industry benchmark), so every off-spec reel wastes it.
Water & wastewater
More sludge through the press in the same operating hours. A wastewater dewatering pilot reached ~2× capacity.
Plastics
Steadier startups and tool changes. Shorter cooling, usually the biggest part of cycle length, where quality allows.
Free Data Health Assessment
See what your line looks like without the drift.
Start with a free Data Health Assessment. We’ll take a closer look and let you know exactly what your own data can do.
Needs 6–12 months of process history with timestamped lab results.
Questions, answered
Frequently asked questions
How is this different from a break-prediction or stop-prediction tool?
Break-prediction and stop-prediction tools try to forecast the event itself and give operators a few minutes of warning, often too few to find a lever. ProcessMiner doesn’t predict the stop. It predicts the quality drift that comes before most stops and flags it before it becomes a stop, with a ranked cause and a recommended adjustment, so operators can correct it while there is still time.
What is an unplanned stop worth?
$20,000 to $200,000 an hour, depending on the process, as an industry benchmark, before counting the off-spec product made on either side of it. On a paper machine, where fiber is roughly half of production cost, every off-spec roll is also fiber that can’t be sold.
How does holding quality raise throughput?
3 ways. Fewer stops, because the drift that leads to them is caught early. Less reprocessing, because less product leaves spec. And steadier running near target, which is where most machines can hold rate. On this platform, throughput comes from holding quality; there is no separate module.
Which capability matters most for throughput?
Real-Time Prediction is the starting point, because it is what sees the drift. PM Vector turns that into a specific setpoint to move to, and Root Cause Analysis shortens the investigation when something does go wrong.
Get in touch
Have a question?
Whether it's our platform, your process, or a free Data Health Assessment you'd like to start, let us know.