We measure productive and non-productive time on the shop floor: how employees and equipment work, assembly operations, waiting and any repetitive actions. We reveal losses and growth opportunities — before changes and after implementation.
No one knows exactly how much time the shop floor actually works, where the minutes of a shift are lost, and how many of them are useful work versus waiting, idle time or supporting operations.
Not consulting. Not an audit. A concrete measurement of what really happens on the floor — with video evidence for every minute of the shift.
We use the existing video surveillance system on the floor and, if needed, connect to signals from the equipment.
We label operations: work, waiting, setup, movement, idle, supporting actions, operator absence.
Productive and non-productive time, utilization, cycle time, recurring delays.
Where the losses are, how big they are, what they translate into in money, and what specifically to improve first.
Once changes are implemented — a repeat measurement with concrete figures for productivity growth.
Assembly area, ~30 workstations, semi-automatic machines. Before the measurement, the production director was certain: “our employees work more than 60%.” The measurement showed — 36%. And the specific points of loss became immediately visible.
Every figure is backed by video — any minute can be reviewed again. This is not an “expert opinion,” but a measurement of fact.
Example: a gas boiler assembly area, 20 employees. Move the slider — see how profit grows as productivity rises.
Calculated without adding headcount, without new equipment, without building a new workshop. Purely through more efficient use of existing time and resources.
| Time study by a specialist | Consulting / audit | Equipment sensors | DRPSoft · video analytics | |
|---|---|---|---|---|
| Time to start | weeks | months | months | 1–2 weeks |
| Cost to start | medium | high | very high | low |
| Monitoring format | one-off | one-off | continuous, but machine only | continuous: people + equipment |
| Sees people and operations | yes (sampled) | yes (sampled) | no — machine only | yes (entire shift) |
| Sees equipment | indirectly | indirectly | yes | yes |
| Objectivity | subjective | expert opinion | sensor data | video evidence |
| Result in money | no | rarely | indirectly | immediately |
Each step is a separate, clear stage with a measurable result. There’s no need to commit to a full “transformation” right away.
Measuring productive and non-productive time on the floor.
Why downtime occurs, what repeats, and where the systemic losses are.
Specific process changes with their expected impact.
Connection to ERP, 1C, BI — shop floor data feeds into the financial loop.
Workload forecasting, a digital assistant for the shift supervisor, and real-time recommendations.
The worker influences pace, idle time, waiting, setup and supporting operations.
You can compare areas, shifts and operations — and see where time is consistently lost.
There’s a plan and there are deviations, but it’s unclear what exactly eats up the shift and where to start improving.
A free initial consultation. We’ll show how the measurement would look on your specific shop floor and propose a work plan with a clear result and timeline.