From invisible downtime to visible gains, how real-time visibility helped Minova eliminate hidden losses, engage operators, and boost profitability.
Client
Industry:
Building Materials
Built-In Value:
Hidden Losses, Real-Time Visibility
Machines
Connected:
Reading time:
3 minutes
Manual reporting and spreadsheets left downtime invisible and improvements unmeasured.
Shoplogix connected Minova’s machines, delivering real-time dashboards, shift-level visibility, and actionable insights.
Uptime increased by 10%+, downtime dropped by up to 75%, and annual savings exceeded $110K.
Like many manufacturers, Minova was under pressure to get more out of its existing operations. But the biggest problem wasn’t the machines; it was the lack of visibility into where time was really being lost.
Manual logs and late reports made downtime reactive, not proactive.
Shift inefficiencies (late starts, early departures, break creep) added up but went unnoticed.
Material delays and maintenance stops caused bottlenecks but lacked measurable impact.
Without real-time data, opportunities for improvement stayed hidden, and productivity slipped away week after week.
to banding downtime.
to weld tip changes.
in break transitions.
to shift transitions
(late starts + early departures).
Overall uptime is stuck at 49%, leaving nearly half of the capacity unused.
Shoplogix connected Minova’s welding machines and stamping presses to its smart factory platform. The shift was immediate:
Real-time dashboards replaced guesswork with live data.
Hourly breakdowns pinpointed inefficiencies invisible in manual reporting.
Benchmarking tools tracked changeovers, transitions, and downtime events to drive improvements.
Operator engagement features gave frontline teams ownership of their performance.
Without real-time data, opportunities for improvement stayed hidden, and productivity slipped away week after week.
Uptime (Availability)
Before:
49% (29.2 hrs/week)
After:
62% (40.6 hrs/week)
Improvement:
+26.5%
Annual Savings:
$65,208
Banding Downtime
Before:
~2 hrs/week
After:
<30 mins/week
Improvement:
75% reduction
Annual Savings:
$65,208
Weld Head/Tip Changes
Before:
~2 hrs/week
After:
<30 mins/week
Improvement:
75% reduction
Annual Savings:
$65,208
Break Transitions
Before:
3 hrs/week
After:
<1 hr/week
Improvement:
66% reduction
Annual Savings:
$11,440
Shift Transitions
(Late Starts & Early Departures)
Before:
~2 hrs/week
After:
<30 mins/week
Improvement:
75% reduction
Annual Savings:
$65,208
Total Impact:
More than
$110K annual savings plus a 10%+ increase in uptime in the first phase alone.
Insights That Drive
Real Change
Coveris transformed its operations by:
Operators took ownership once they could see their impact live.
Cutting just minutes per shift added six figures to annual savings.
Teams became motivated by seeing results in real time.
Continuous improvement became measurable.
Your Plant Might Have the Same Hidden Losses
If your team still relies on spreadsheets or delayed ERP data, chances are you’re losing more than you realize:
Downtime you can’t see is downtime you can’t fix.
Shift inefficiencies, late starts, early departures, and extended breaks are quite profit killers.
Manual reporting leaves you reacting instead of improving.
Minova’s story shows what happens when those blind spots are removed:
lost minutes turn into recovered hours, and recovered hours turn into
serious savings.
Building a Culture of Continuous Improvement
The lesson: Data by itself is just numbers. Actionable insights drive change. And with Shoplogix, Minova transformed hidden downtime into measurable savings and a stronger future.
Hop on a no-commutment strategy call with our team and we will advise you.
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