The True Cost of a Downtime Minute
What is the cost of downtime in high-need manufacturing?
The cost of downtime in high-need manufacturing, such as Food & Beverage, FMCG, and Plastics, includes the direct labor and repair expenses plus the "Hidden Factory" losses of missed throughput, material scrap, and late-delivery penalties, often totaling $5,000 to $10,000 per hour.
For Paula (the Strategic Leader), every minute of "Decision Latency" is a direct hit to the bottom line.
In a siloed factory, this latency is the time wasted while a supervisor notices a red dashboard and manually radios a technician.
Fabrico eliminates this tax by ensuring that every OEE deviation instantly triggers a prioritized Work Order in the Field-Ready CMMS.
Why Visibility Alone Fails High-Need Manufacturers
Most OEE tools act as "Digital Scoreboards"—they tell you that you are losing money, but they provide no tools to fix the problem.
In high-speed lines, a 5% drop in performance is often the first sign of a mechanical failure that will occur within 48 hours.
If your OEE data is disconnected from your maintenance team, this "Early Warning" is lost in a post-shift report.
Fabrico acts as a System of Action, using real-time machine signals to dictate maintenance priority, ensuring your team focuses on the Value Fulcrum, the high-impact tasks that protect your effective runtime.
Comparison Matrix: Hardware Scoreboards vs. Fabrico System of Action
| Feature |
Hardware Scoreboards (Vorne XL) |
Standalone OEE Apps |
Fabrico (System of Action) |
| Primary Goal |
Floor Awareness |
Executive Reporting |
Operational Uptime / Action |
| Maintenance Link |
None |
Manual / Siled |
Native Integrated CMMS |
| Micro-stop RCA |
Basic / Manual |
Data-Only |
Advanced Visual Zoom-In |
| Response Trigger |
Visual Alert Only |
Email / Notification |
Automated Mobile Work Order |
| Mobile UX |
N/A |
Browser-Based |
Field-Ready Native App |
| Decision Latency |
High (Hours) |
Moderate |
Zero (Automated) |
Reclaiming the Hidden Factory with Visual Evidence
In sectors like Plastics or FMCG, micro-stops are the primary source of revenue leakage.
Traditional sensors know when a machine stops, but they cannot tell you if the cause was a material jam or a misaligned guide rail.
Fabrico’s Inefficiencies Zoom-In (Computer Vision) module captures high-definition video of every downtime event.
This visual truth ends the "Blame Game" between production and maintenance shifts and provides the evidence needed for permanent KAIZEN fixes.
Instead of guessing, Mike (the Tactical Manager) can "Zoom-In" to see the specific mechanical friction, ensuring the repair is permanent.
Strategic ROI: Moving Beyond the Score
For Paula, the decision to implement an integrated platform is about "Capacity Reclamation."
By reclaiming just 5% of Availability and Performance through integrated action, she can increase total plant throughput without purchasing a single new machine.
This efficiency directly lowers the Maintenance Cost per Unit and ensures that her capital assets reach their full residual value.
As the factory builds its 12-month data layer, it creates the foundation for future AI-driven optimizations on the roadmap.
Stop managing your losses on a scoreboard. Start engineering uptime with a System of Action.
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