Find the hours you’re losing. Turn them into scheduled work and margin.
MACH is a machine monitoring, scheduling, and analytics platform for manufacturers. Customers won't accept another price increase, and you don't have the data to justify buying more equipment. The margin has to come from capacity you already own. MACH shows where every machine loses time and why, catches a slipping schedule while the shift can still recover, and measures each improvement against a locked baseline, then keeps checking that it holds.
See where the time goes.
Running, idle, down, or in changeover, read from the PLC. Operators classify a stop in two taps while the machine is still stopped.
See Monitor → ScheduleCatch the slip at 10am, while there’s time to fix it.
Drag jobs onto machines or let the auto-scheduler place them. Progress updates as orders run, so a slipping job shows up hours earlier.
See Schedule →Prove what improved, in dollars.
Write your own KPI formulas, then build custom reports and dashboards on them. Find CI projects, run them, and measure every change in dollars.
Analytics · Reports & Alerts · CI ProjectsAsk the floor a question.
Which press improved most last month? Where's the order due Friday? Virgil answers from your own data, shows where every number came from, and never changes anything.
Meet Virgil →Coming next: MACH Maintain, asset management and work orders connected to the floor and the schedule.
Last updated: October 13, 2026
What changes with MACH? More hours you can schedule and sell, on the same floor.
How do the MACH apps work together? One record of the floor, and every app reads from it.
Monitor reads machine state from the PLC and asks the operator why a machine stopped while it's still stopped. Schedule plans the work and tracks each order's progress as the floor runs it. Both write to the same history, and Reporting & Analytics turns it into the dashboards, reports, alerts, and CI projects your team works from.
How long does this job really take on Line 3 with this material? Most schedules run on a standard rate and an educated guess. MACH records what every job actually took against what was planned, and once a job is running, the board projects its finish from its real pace. Your planners can see exactly where the standard rates are off and fix them.
Monitor and Schedule each work on their own. Start with whichever solves your most pressing problem and connect them when you're ready to close the loop. MACH Maintain comes next: a breakdown logged at the kiosk opens a work order, and preventive maintenance lands on the schedule as a block the planner can't move.
Manufacturing operational intelligence is the real-time capture of shop floor data (machine state, operator context, and production results) and its delivery to the people who make decisions from it. MACH is an operational intelligence platform that connects directly to the PLC layer and works with or without an MES.
Who is MACH for? Operations, plant, finance, and CI leaders.
When margins tighten, you need to know where capacity is being lost.
Which shift lost what, and why? Without machine data, that question turns into a debate. MACH has the answer before the meeting, by machine, shift, and reason.
See the VP of Operations page →When leadership asks why performance was down, you need data you can defend.
You see the problem at 9am, while there’s still time to fix it, and you walk into the review with what happened on each machine and shift.
See the Plant Manager page →The board wants to know where the margin recovery comes from. Your reports can’t say.
Most operations can’t tell a capacity problem from an execution problem, and the two need very different fixes. MACH shows which one you have, with the numbers to back it.
See the Executive page →The hard part of CI is the ROI conversation.
There are really two. Before the project, you need a credible number to get the budget. After it, someone asks you to prove it worked. A baseline locked from machine data answers both, and MACH keeps checking that the gain holds.
See CI Projects →Does MACH need an MES or ERP? It works with both, or without them.
MACH connects directly to your machines and captures what an MES or ERP can't see: why each machine stopped and how each job really ran. If you already run one, MACH works alongside it and fills the gap between the floor and your reports. If you don't, MACH runs on its own and becomes your system of record from day one. You don't replace anything, and you don't need anything else in place first.
| Capability | Monitor | Schedule | Reporting & Analytics |
Complete |
|---|---|---|---|---|
| Floor visibility | ||||
| Real-time machine monitoring (PLC) | ✓ | – | – | ✓ |
| Two-tap downtime classification | ✓ | – | – | ✓ |
| OEE analytics & KPI reporting | ✓ | – | – | ✓ |
| Operator kiosk (context capture) | ✓ | – | – | ✓ |
| Floor display dashboard | ✓ | – | – | ✓ |
| Automated production counting | ✓ | – | – | ✓ |
| Production scheduling | ||||
| Visual production scheduler | – | ✓ | – | ✓ |
| Intelligent auto-scheduling | – | ✓ | – | ✓ |
| Machine constraints & changeover | – | ✓ | – | ✓ |
| Connected-line scheduling | – | ✓ | – | ✓ |
| Duration prediction (from process routes) | – | ✓ | – | ✓ |
| Multi-step jobs from your routings | – | ✓ | – | ✓ |
| Order management (split, combine, ERP sync) | – | ✓ | – | ✓ |
| Operator kiosk (execution at the machine) | – | ✓ | – | ✓ |
| Standalone scheduling (no floor data) | – | ✓ | – | ✓ |
| Closed-loop integration | ||||
| Monitoring ↔ Scheduling loop | – | – | – | ✓ |
| Reporting & analytics (included with every product) | ||||
| Custom KPI builder (your formulas) | ✓ | ✓ | ✓ | ✓ |
| Dashboards & data visualization | ✓ | ✓ | ✓ | ✓ |
| Every shift’s history, kept and reportable | ✓ | ✓ | ✓ | ✓ |
| Machines and plants defined once | ✓ | ✓ | ✓ | ✓ |
| Custom order fields and materials | ✓ | ✓ | ✓ | ✓ |
| Corrections with an audit trail | ✓ | ✓ | ✓ | ✓ |
| Scheduled reports by document & email | ✓ | ✓ | ✓ | ✓ |
| Floor & schedule alerts | ✓ | ✓ | ✓ | ✓ |
| CI Projects (baseline, savings, sustain) | ✓ | ✓ | ✓ | ✓ |
| Virgil AI assistant | ✓ | ✓ | ✓ | ✓ |
| Platform (every product) | ||||
| Multi-plant console (one login, role-based access) | ✓ | ✓ | ✓ | ✓ |
| Security, SSO & access control | ✓ | ✓ | ✓ | ✓ |
| Admin & self-service configuration | ✓ | ✓ | ✓ | ✓ |
| Open APIs & data export | ✓ | ✓ | ✓ | ✓ |
| MCP connection (bring your own model) | ✓ | ✓ | ✓ | ✓ |
Buy a product and you get every feature in it. Reporting & Analytics, including Virgil, comes with every MACH product at no additional charge.
One login for every plant. Nothing flows back to your machines.
Data flows out from your machines, and MACH never opens a connection into your PLCs or OT network. Your team signs in once and moves between plants, you decide who sees what, and data is encrypted at rest and in transit.
- Outbound-only data flow. No inbound connections to your PLCs or OT network.
- One login across every plant. Role-based access controls who sees what (admins, planners, viewers) across every facility.
- Kiosk tablets and floor displays need no login at the cell.
- Every administrative change tracked in a dedicated audit log.
You know what your products cost in theory. Do you know what they cost to make?
Standard costing tells you what a product should cost. It doesn't see how often you change over between jobs, the disruption when material arrives late, the overtime when a run takes longer than estimated, or the capacity your least profitable SKU uses up. Those costs are real, and they never show up in the model.
MACH already captures the production data that cost-to-serve is built on. With it, you'll see which products make money, which ones your best work is subsidizing, and which customers add margin or erode it. That changes how you price and what you choose to make.
Cost-to-serve analytics is where MACH is headed next. When it ships, it reads the data Monitor and Schedule capture today, so there's nothing new to implement.
We wrote about what this looks like on a real floor: What the job actually cost.
$500K–$2M: Kinetech customer benchmark. See the cost-to-serve analysis.
Questions about MACH.
How does MACH help recover margin?
It shows where every machine loses time and why, so you can win back hours on the machines you already own. Those hours go back on the schedule as work you can ship, and CI projects measure each improvement in dollars against a locked baseline.
Is MACH an MES or ERP? Does it require one?
No. MACH connects directly to your machines and captures what an MES or ERP can't see: why each machine stopped and how each job really ran. If you already run one, MACH works alongside it. If you don't, MACH runs on its own as your system of record from day one. You don't replace anything, and you don't need anything else in place first.
How does MACH connect to machines on the shop floor?
MACH connects to machines via an edge gateway installed on-site that reads from the PLC layer. The connection is outbound-only, so it works within standard IT security policies, with no firewall exceptions or inbound ports.
What does MACH cost?
MACH is priced per work center per month on annual billing, with volume tiers that lower your rate as you scale. Every product includes unlimited users, orders, and features, plus Reporting & Analytics and the Virgil AI assistant at no additional charge. See full tier pricing.
How does MACH track continuous improvement projects?
When a project starts, MACH locks a baseline from the machines’ own data and measures every period after against it, with a plain verdict on whether the change is meaningful. You enter your own cost assumptions to put a dollar figure on the savings, and after the project closes, MACH keeps checking that the gain is holding. Run it with the method your team already uses, like SMED, A3, PDCA, or kaizen. See CI Projects.
Can I use my own AI model with MACH?
Yes, through MACH’s MCP (Model Context Protocol) server. Bring Claude, ChatGPT, or your own model, and it can use MACH’s read-only tools to ask about KPIs, downtime, period comparisons, and schedule adherence. Your admin approves the app first and can revoke it at any time, and each person signs in as themselves, so the model sees only what that person could see in Hub. Meet Virgil.
What production data does MACH capture?
MACH captures machine state (running, idle, down), operator-logged downtime root causes, production counts per job, changeover time per order, and schedule attainment by line and shift. All data is available in real time before the shift ends.
How long does MACH implementation take?
MACH deployments begin with a 90-day Pilot with defined scope and measurement window. Most production monitoring deployments are live within the first 30 days of the Pilot.
The meter is running. Book a diagnostic.
We run a Shop Floor Diagnostic against your floor. One-hour call to understand your situation, then a written assessment of where your losses actually are.
Either outcome is professionally defensible. If the numbers justify action, you have the case. If they don't, you have the data.