With real-time scorecards and automated loss tracking from Shoplogix, Brampton Brick elevated operational performance, leveraged machine truth as the source for communication, and empowered every level of the organization to make data-driven decisions and solve problems as they occurred.
Client
Industry:
Building Materials
Built-In Value:
Operational Excellence, Continuous
Improvement, Real-Time Visibility
Machines
Connected:
Built-In Value:
Operational Excellence, Continuous
Improvement, Real-Time Visibility
Brampton Brick was operating with a number of different systems across its divisions. Through discussions with Shoplogix, a short term, low risk, pilot project was outlined. The Pilot Project – focused on offering a true baseline and comparison to the current processes and systems,and the ability to uncover hidden losses and quantify the losses that were hard to measure in the previous systems.
The pilot project uncovered that granular losses were not measuring the true impact; Short, frequent disruptions—micro-stops and speed loss—went undetected in the previous data collection efforts and often did not show up on the top downtime pareto charts.
Teams knew productivity was being impacted, but without the data to validate where and why, decisions were based on assumptions and gut feel rather than measurable evidence.
Meanwhile, manual reporting processes led to delays in communication and lack of trust in the data. The result: no clear path to improvement, no alignment across plants, and frontline operators disconnected from corporate KPIs.
One of the most revealing examples involved a dehack robot. Every hour, the operator had to stop production to correct alignment—triggering safety interlocks and halting the line.
Because these frequent micro-stoppages didn’t exceed the 5-minute reporting threshold, they were rarely logged or analyzed. The line appeared to be running well, but actual availability told a different story.
The issue wasn’t performance—it was availability. Everyone knew it was occurring and it was a main source of the problem, but no one had the data to quantify how much of a problem it really was.
Communication Tool for the Operator
Within days, Shoplogix compared the systems and revealed that on the avgerage shift over 1 hour and 20 minutes of previously untracked downtime was under reported or not captured at all. The pilot project provided the operators with a source of truth, and now the plant could measure the true impact of these losses and drive communication around the data. No more guess-work, and everyone knows exactly what is happening through the data.
Real-time scorecards and visual dashboards replaced static reports. Operators, supervisors, and executives all viewed the same live KPIs, tailored to their role. This alignment made it easier to identify bottlenecks, share best practices, and hold productive daily reviews.
“Visual scorecards give every team immediate feedback. They’ve completely changed how we communicate.”
VP of Operations
With 8 plants connected on the same platform, Brampton Brick standardized how they define, measure, and report performance. From the plant floor to the boardroom, teams now speak the same operational language and focused on the same goals.
Identifying Speed Loss and eliminating Micro-Stops helped reclaim productive time across all 8 sites.
Easy-to-use tools and real-time feedback created strong frontline engagement and ownership. The high adoption demonstrates that the employees were able to quickly utilize Shoplogix and found it easy to adopt.
Shoplogix replaced after the reports and decision making with live insights, enabling faster, more confident decisions.
What started as a Pilot project to compare to the current systems in place, became a culture transformation. Brampton Brick’s journey with Shoplogix laid the groundwork for true operational excellence—where continuous improvement isn’t a project, but a habit.
With every line connected and every team engaged, Brampton Brick is equipped to evolve, adapt, and grow—no matter what challenges come next.
Hop on a no-commutment strategy call with our team and we will advise you.
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