Services · Plant KPI monitoring
Production monitoring software for Indian plants, without a new control room
- What will be running
- Steam, power, downtime and yield per shift, read from existing meters and registers, on your phone
- By when
- First KPI live in 30 days; full shift report in 60
- What it saves
- Target: 3 to 6% off energy cost per tonne, agreed in writing; downtime causes named within the shift
Works with what you already have
What runs on Excel today
The boiler log is a register. The energy meter is read once a day by whoever is passing. Downtime is a reason written in Hindi in the shift book, if it is written at all. Yield is calculated at month end, when it is too late to do anything about last Tuesday.
You find out steam efficiency fell when the fuel bill arrives.
What we deploy
Agents, not features. Each one is listed when it is live.
Shift register agent
Reads the boiler log, energy meter and production register at shift change, by photo or export. Flags gaps and impossible values before they become the monthly number.
Energy per tonne agent
Steam and power per tonne of output, per shift, per line, against last month and the best shift on record. A drop is a message within the shift, not a line in a quarterly review.
Downtime agent
Every stoppage with a start, end and reason from the shift book, coded and ranked. By week two you know the three causes that cost you most.
Shift report agent
One message at shift end to the plant head, one summary at 9 am to you.
What it saves
Energy is the usual first win. In a plant spending ₹1.5 Cr a year on fuel and power, 3 to 6% is ₹4.5 to 9 lakh, from running the best shift's settings more often. Downtime falls because the reasons are counted. Yield improves because losses are seen the day they happen.
The saving is agreed in writing before we build, in energy per tonne, downtime hours or yield. Not met in 90 days: we keep working at no charge for up to 90 more days until it is. The guarantee covers the first agent.
The guarantee
In writing, before we build.
One number for the first agent, how it is measured, and the date. Not met in 90 days from go-live, we keep working at no charge for up to 90 more days until it is.
How the first 30 days go
Plant visit. We walk the line with the plant head, photograph every register and meter, and pick the one KPI that moves money.
Shift register agent live. First week of data checked with the supervisors who wrote it.
Energy per tonne live, with the best-shift benchmark.
Shift report at shift end. Weekly brief starts.
Every Monday
The weekly brief
One page. What is running, what it did, what we need from you. Figures illustrative.
Four things no vendor will put in a contract.
30
Days to the first agent
Not a demo. A date, in the proposal you sign.
₹
The saving, in writing
Agreed before we build. Not met in 90 days: we keep working at no charge for up to 90 more days.
1
Visit before any fee
We come to you. The first day costs nothing.
52
Briefs a year
Every Monday: what is running, what it did, what we need.
Questions promoters ask
Do we need new sensors or a SCADA system?
Usually not for the first KPIs. Boiler logs, energy meters and shift registers already hold the numbers. We read them, by photo, by meter export or by a small gateway where one exists. Sensors come later, only where the saving justifies them.
What is OEE and do I need it?
Overall equipment effectiveness: availability times performance times quality. For most promoters the useful number is simpler: tonnes per shift, energy per tonne, and why the line stopped. We start there.
Can the agent tell me why steam efficiency dropped?
It tells you when, on which boiler, during which shift, and what else changed: feed water, fuel lot, load. The why comes from your boiler engineer, faster, because the agent has already narrowed it down.
How does this differ from Evocon, Tractian or an OEE SaaS?
They sell a dashboard and expect your team to feed it. We make the numbers arrive, check them, and send you the shift report. The saving is agreed in writing before we start.
Tell us where the money leaks.
Tell us where the money leaks. A 30-minute call: we ask about the business, you ask about us. If AgentJi is not the right answer we will say so and tell you who is.