Modules
Seven product modules — start with what hurts most, expand as you grow. Each module works standalone and shares the same data backbone.
Finite-capacity scheduling that stays honest
Drag-and-drop planning with shift calendars, changeover intelligence, and real-time rate feedback from the floor. Replace the planner's Excel with a living schedule.
Timeline & Kanban
Drag-and-drop timeline and Kanban views for production scheduling. Assign orders to lines, set sequences, and publish schedules that operators see instantly. Horizon planning lets you look days or weeks ahead.
Constraint-based sequencing
Changeover minimisation, due-date priority, item group affinity, and custom rules automate the tedious sequencing decisions. Changeover matrix templates encode time costs by product family, allergen class, or colour.
Freeze windows & adherence
Protect today's plan while allowing soft changes for tomorrow. Schedule adherence tracking compares planned vs actual start, end, and quantity for every job — updated in real time from machine counters.
Live rate feedback
Actual run rates from counters continuously adjust expected durations. If the line is running slow, the schedule reflects it immediately — the plan becomes a living document, not a snapshot.
Real-time visibility into what's running and whether you're on track
Live line status, job progress, and gap explanation — so management gets trusted answers without walking the floor.
Live line status
Every line shows its current state in real time: Running, Stopped, Idle, Starved, or Blocked — derived from machine counters and optional run/stop signals. Updated via WebSocket within seconds.
Progress vs target
Active orders display current good count, target quantity, progress percentage, and estimated completion time. Updated live from the shop floor.
Gap analysis
Explains the difference between planned and actual: downtime minutes, speed loss minutes, and scrap — so you know why you're behind, not just that you are.
Plant overview
A live, interactive model of your entire plant. See machine states, active orders, operator assignments, and KPIs across every line — all on a single screen with drill-down.
Operational master data
Product tags, ideal rates, UoM conversions, and changeover families — maintained with validation rules and duplicate detection. Counters help infer ideal rates and highlight inconsistencies.
OEE-lite with auto-detection and root-cause analysis
Auto-detect downtime from counters, capture reasons in one tap, and see exactly where your output is lost — availability, performance, and quality.
Auto downtime detection
Machine counters detect state changes automatically — running, idle, or down — based on configurable thresholds. No manual stop/start required.
1-tap reason capture
When downtime starts, the operator tablet pushes a reason prompt with hierarchical categories. Add notes and photos for context. Optionally tag 'maintenance needed' to create a work request.
OEE-lite dashboard
Availability (downtime), Performance (speed loss), and Quality (scrap) — broken down by line, shift, product, and time period. Loss tree analysis shows where the biggest opportunities are.
Trend analytics
OEE trends, throughput comparisons, scrap analysis, and shift benchmarks — all built from live production data. Filter by line, item group, or date range and export reports.
Digital changeovers, batch records, SOPs, and shift handovers
Replace paper checklists with enforced digital workflows. Every step is timed, every field is required, and every signature is traceable.
Changeover & line clearance checklists
Digital checklist templates per line and product family with required fields, pass/fail criteria, and photo evidence. QA release gate prevents the next job until clearance is complete.
Digital batch records
Batch record templates with required steps and measurement points. Auto-fill timestamps, machine data, lot IDs, and counts. Incomplete or unsigned steps are flagged immediately.
Shift handover logs
Structured handover forms per line: top issues, actions taken, risks, and material shortages. Auto-attaches the shift's downtime Pareto and quality alarms for context.
Work instruction versioning
Digital work instructions with rich text, images, and step-by-step checkpoints — all versioned. Link required versions to products or orders. Proof-of-use records complete the audit trail.
Role-based e-signoff
Multi-level approval workflows: operator confirms completion, supervisor reviews, QA approves. Every signature is timestamped and tied to the user's authenticated session.
Structured quality checks, SPC-lite, and deviation management
Move from paper QC sheets to scheduled in-process checkpoints with trend detection, defect coding, and corrective action tracking.
In-process checkpoints
Checkpoint schedules triggered by time, quantity (from counters), or batch events. Operators enter measurements on the tablet, linked to batch, order, and timestamp.
SPC-lite alerting
Out-of-spec alerts, trend warnings (e.g., 3 consecutively increasing points), and control limit violations. Early detection prevents scrap before it accumulates.
Scrap & defect codes
Quick scrap reason capture with structured defect codes. Every scrap event tied to batch, machine, operator, and time. Top loss tree reveals patterns and correlations.
Deviation & CAPA-lite
Raise deviations from any event — downtime, QC fail, scrap spike. Assign owner, due date, and checklist. Effectiveness checks trigger automatically after configurable intervals.
Fill weight & variance control
Weight or volume checkpoints with SPC-lite trending. Detect giveaway (overfill) and underfill risk. Correlate with changeovers, shifts, and material batches.
Compliance-grade audit trail
Immutable logging of every critical event with user identity, timestamp, and full context. Audit export per batch generates print-ready documentation for regulatory review.
Lot traceability, inventory accuracy, and line-side replenishment
Close the gap between ERP inventory and physical reality — from lot capture at batch start to FEFO enforcement and digital kanban at the line.
Lot-at-start capture
Operators scan or enter raw material lots at batch start. Finished goods lots are recorded at batch end. Full genealogy chain: RM lots → batch → FG lots → shipments.
Genealogy graph & recall export
Trace any lot forward and backward through internal transformations. Recall audit export generates a one-page report with all affected lots, quantities, and destinations.
Consumption tracking
Confirm staged lots at batch start, auto-calculate expected consumption from counters and BOM, and capture substitutions. Push reconciled data to ERP.
FEFO enforcement
Line-side staging board shows lots sorted by expiry. Warn when non-FEFO lot is used (override with reason). Alerts for lots approaching expiry in staging or quarantine.
Line-side digital kanban
Min/max bin levels per item. Operator taps 'bin empty' or scans QR — replenishment task created instantly. Track response time and link starvation downtime to replenishment latency.
Warehouse workflows
Barcode-driven receiving, putaway, picking, shipping, and cycle counts with full lot tracking. Offline-first: every action queued locally and synced when connectivity returns.
Operational batch costing and maintenance-lite
Know the true cost per good unit and connect maintenance actions to downtime events — without full ERP cost accounting or heavyweight CMMS.
Batch cost per good unit
Compute cost per good unit from material (standard or captured lots), labour (shift allocation or operator check-in), and yield (good/scrap from counters). Dashboard shows top drivers.
Cost comparison analytics
Compare cost per good unit across products, lines, shifts, and time periods. Surface where margin is being lost without full cost accounting complexity.
Work requests from downtime
From any downtime event, tap 'Create work request' — pre-filled with machine, time, duration, and reason. Maintenance team sees prioritised requests with full production context.
Preventive maintenance calendar
Simple PM calendar with checklists for recurring maintenance tasks. Assigned to technicians with due dates. Maintenance history per machine builds over time.
MTBF / MTTR dashboards
Mean time between failures and mean time to repair derived automatically from downtime events and work completion timestamps. Data-driven repair vs replace decisions.
AI that understands your factory
Frontlink's AI agents have deep contextual access to every table in your databases — production orders, machine telemetry, quality records, inventory movements, and operator sessions. They don't work from summaries; they query your actual operational data.
Ask a question like 'Why did OEE drop on Line 3 last Tuesday?' and the agent traces the answer across machine state changes, downtime events, changeover logs, and quality holds.
Agents don't just read data — they take action. Schedule maintenance, adjust sequences, or generate reports. Every action follows safety boundaries, produces an audit trail, and supports human-in-the-loop approval.
Full Database Contextualisation
Agents understand your complete data model — from raw telemetry to ERP-synced orders. No manual data mapping required.
Natural Language Queries
Ask operational questions in plain language. The agent translates intent into precise database queries and returns structured answers.
Autonomous Task Execution
Agents execute multi-step tasks: adjusting schedules, triggering reports, updating configurations — all within defined operational boundaries.
Audit Trails & Safety Boundaries
Every agent action is logged with full context. Role-based boundaries and human-in-the-loop approval prevent unintended consequences.
Operational Intelligence
Pattern detection across production runs, shift performance, and quality trends. Agents surface insights you didn't know to look for.
The operator's command centre
A tablet-optimised interface that gives operators real-time visibility into machine performance, material consumption, and quality requirements — without leaving the production line.
Real-time Monitoring
Live OEE, throughput, and machine state at a glance. Operators see exactly what their line is doing — running, idle, or down — with second-level granularity.
Material Issue (Weigh & Dispense)
Guided weigh-and-dispense workflows for precise material consumption. Scale integration ensures accuracy, and every dispense is recorded against the production order.
Quality Control
In-line quality checks triggered by time, quantity, or batch events. Operators complete digital forms, capture photos, and submit results — all without paper.
Label Printing
Print product labels, batch labels, and pallet tags directly from the operator screen. Templates are configured per item and line, with dynamic fields filled automatically.
Downtime Monitoring
Operators register downtime reasons directly from the tablet when a machine stops. Categorise by cause and feed accurate data into OEE and availability reports.
Custom Screens
Build tailored operator views without code changes. Surface the exact data, forms, and actions each workstation needs — from SOP checklists to machine-specific dashboards.
Platform foundations
Modular architecture
Multi-tenant, config-driven design that scales from one line to a global footprint without code forks. Start with one module and expand when you're ready.
Workflow engine
Visual workflow builder for approvals, escalations, and exception handling across plants. Route decisions based on roles, thresholds, and production context.
Unified data backbone
Real-time events contextualised in a shared namespace. ERP, machines, and people speak the same language — one PostgreSQL database with row-level tenant isolation.
ERP integration
Bi-directional sync with Exact Online and other ERPs. Orders, items, BOMs, and confirmations flow automatically — production reality stays aligned with finance.
Offline-first resilience
Edge gateways and the warehouse PWA use store-and-forward queuing. Data is never lost even when connectivity drops — operations continue uninterrupted.
High-volume telemetry
TimescaleDB handles millions of sensor readings per day with automatic compression and retention policies. Machine state changes reach dashboards in under a second.
See Frontlink in action
Book a personalised demo or explore the platform architecture to understand how it all connects.