How It Works
The Operational Excellence Execution Platform
This is where improvement gets executed. Three modules — LOGS, IDA, and DOCS — work together in a continuous loop to capture knowledge, investigate root causes, and turn validated insights into living procedures. Systematic. Strategic. Controlled.
Two Worlds That Need to Connect
Every operation has two data streams. Most companies only connect one.
Dashboard Reality
Shop Floor Reality
Both sides generate data. Neither side sees the other.
Your operation runs on two types of data:
Machine Data — The What. Temperatures, pressures, speeds, counts. Terabytes telling you what happened.
Human Knowledge — The Why. The bearing that sounds different. The adjustment that works on humid days. Context no sensor captures.
You've invested millions in capturing machine data. But the human side? It lives in people's heads, disappears at shift change, and walks out the door at retirement.
That's the gap. Not a technology gap—a knowledge gap. And it costs you repeat failures, slow root-cause analysis, and improvements that don't stick.
Oppr closes that gap.
Why Traditional Approaches Fail
You've Tried This Before.
Here's Why It Didn't Work.
Every manufacturer has attempted to capture operator knowledge. The approaches fail for predictable reasons.
Knowledge disappears at shift change
What you tried
Paper logbooks, shift handover forms
Why it failed
Takes too long, inconsistent, nobody reads them
With Oppr
20-second voice capture. AI structures and tags automatically. Searchable forever.
Root cause takes weeks to find
What you tried
Manual data pulls, meetings, tribal knowledge
Why it failed
Human context isn't in any system. Data exists in silos.
With Oppr
Unified timeline connects human observations to machine data. Ask questions in plain language.
Expertise walks out at retirement
What you tried
Documentation projects, knowledge transfers
Why it failed
Results in PDF graveyards nobody reads. Can't capture tacit knowledge in interviews.
With Oppr
Knowledge captured continuously in the flow of work. Always current. Always accessible.
Improvements don't stick after Kaizen
What you tried
SOPs, training programs, audits
Why it failed
Documentation doesn't match reality. Procedures written by people who don't do the work.
With Oppr
Living documentation that updates based on what actually works. PDCA that actually cycles.
The Core Innovation
The Unified Timeline
Human observations and machine data on one time axis.
Correlatable. Queryable. Connected.
Your machine data shows two temperature spikes…
Why This Matters
When you investigate an issue today, you query your machine systems. You see the temperature spike at 2pm. But you don't see the operator's observation from 8am that “the material looked different today.”
That observation exists—but it's trapped in someone's head, mentioned verbally at shift change, or scribbled in a notebook nobody reads.
The unified timeline changes this. Every observation is timestamped, tagged to equipment, and available for correlation. When the temperature spikes, you see the human context that explains it.
An operator's observation automatically links to machine data from two days later—revealing a cause-and-effect relationship that was always there, but never visible.
The Platform
Three Modules, One Workflow
From capture to action. Each module serves a purpose. Together, they close the loop.
Capture Knowledge in 20 Seconds
Operators speak what they notice — in any language. AI does the rest: transcription, structuring, tagging. Unlike unstructured feedback, LOGS creates a continuous stream of structured, tagged, time-stamped observations — the foundation for systematic analysis.
Voice, photo & text capture
Any language, auto-translated
AI structures automatically
Equipment tags, timestamps, categories
20 seconds, not 8 minutes
Zero workflow disruption
"Bearing on Line 3 sounds higher than normal"
Speak what you notice. Any language.
What LOGS Captures
Voice observations
Any language, any accent. AI transcribes and structures automatically.
Photo evidence
Defects, gauge readings, equipment conditions. AI extracts data from images.
Quality checks
Structured or unstructured. Integrates with existing quality workflows.
Events and anomalies
Downtime, near-misses, deviations. Captured in the moment.
Before
“The operator mentioned something about the bearing at shift change. Nobody wrote it down. A week later, the bearing fails.”
With LOGS
“The operator voice-logged ‘Bearing on Line 3 sounds higher-pitched than normal’ in 20 seconds. It’s timestamped, tagged, and waiting to be correlated.”
Your AI Co-Pilot for Root Cause
Your AI investigation engine. Ask questions in plain language. IDA connects human observations with machine data to find root causes, surface patterns, and accelerate every investigation. This is where gut feelings become confirmed causes.
Natural language queries
No SQL, no dashboards needed
Cross-data correlation
Human context meets machine data
Pattern detection
Recurring issues surface automatically
What happened before the quality drop on Line 2?
Analyzing 142 observations and machine data...
Ask in plain language. No SQL. No dashboards.
What IDA Does
Natural language queries
Ask questions in plain language. No technical expertise required.
Cross-data correlation
Connects human observations with machine data automatically.
Pattern detection
Surfaces recurring themes, anomalies, and correlations.
Root cause acceleration
Finds the human context that explains machine data anomalies.
Before
“Investigation takes weeks. Engineers dig through dashboards, interview operators, and still miss the human context that explains the data.”
With IDA
“Ask ‘What happened before the quality drop on Line 2?’ and IDA shows operator observations alongside machine data — root cause in hours, not weeks.”
Living Documentation at the Point of Work
The final piece of the execution loop. Procedures that update when better approaches are validated. Accessible via QR codes on equipment. Validated insights become permanent, living procedures accessible at the point of work.
Living procedures
Updates from validated insights automatically
QR code access
Right info at the machine, instantly
Expertise preservation
Knowledge stays when people leave
SOP-042
Line 3 Startup
Scan. Get the right procedure. At the machine.
What DOCS Provides
Living procedures
Documentation that updates from validated insights and actual practices.
Point-of-work access
QR codes on equipment link to relevant knowledge instantly.
Searchable knowledge base
Find what you need with natural language search.
Expertise preservation
Tacit knowledge captured and accessible to everyone.
Before
“The procedure says one thing. What we actually do is different. New operators follow the procedure, get it wrong, then learn the ‘real’ way from colleagues.”
With DOCS
“Documentation reflects what actually works. When the ‘real’ way proves better, it becomes the documented way. New operators learn the right approach from day one.”
The Closed Loop
From Capture to Analysis to Implementation
Each module feeds the next. The loop closes. Value compounds with every cycle.
Capture
Knowledge enters the system
Every observation is a data point that didn't exist before. The more you capture, the richer the dataset for analysis.
Analyze
Patterns surface automatically
IDA finds correlations humans miss — connecting observations across shifts, time periods, and equipment.
Implement
Improvements become permanent
Validated insights become living documentation. What's learned stays learned. Accessible at the point of work.
Better practices lead to better observations — the loop continues
Case Study
Saving the "Golden Recipe"
How a PVC pipe manufacturer preserved decades of operator expertise before it walked out the door.
The Challenge
A PVC pipe manufacturer was losing their 'golden recipe' — the specific combination of settings, timing, and adjustments that produced perfect output. Only two operators knew it. One was retiring in 6 months.
Month 1–2: Capture
Both experienced operators used LOGS to voice-capture their observations during production. Every adjustment, every observation about material behavior, every trick they'd learned over decades — captured in 20-second voice logs while they kept working.
Month 3: Analyze
As data accumulated, IDA correlated operator observations with machine data. Patterns emerged: the golden recipe wasn't just settings — it was a sequence of micro-adjustments based on material behavior that no documentation had ever captured. First measurable ROI appeared here.
Month 4: Implement & Validate
DOCS created living procedures that captured the complete golden recipe — including the contextual adjustments. New operators achieved consistent quality within weeks instead of the usual 6–12 months of trial and error.
We thought we were documenting a recipe. What we actually captured was 30 years of intuition that no interview or training session could have extracted.
Start Small. Prove Fast.
Deployed in Weeks, Not Months
No IT project. No complex integration. Start with one line, prove value, then scale what works.
Knowledge Risk Assessment
~2 Weeks
We assess where your critical knowledge lives, identify key-person dependencies, and pinpoint the highest-value starting point.
Single-Line Pilot
First 2 Months
Deploy on one production line. Train operators in 15 minutes. Value starts from day one — every captured observation builds your knowledge base.
Analysis & First Results
Month 3
Review captured data, surface first insights, and demonstrate measurable value. First ROI typically appears here — prove it before expanding.
Scale What Works
Onwards
Expand to additional lines, shifts, or sites based on proven results. ROI compounds as the knowledge base grows — no big bang required.
No IT Project
Cloud-based, mobile-first. Works on existing devices. No hardware installation.
Optional Integration
Start standalone. Connect to historians/MES when ready. Integration enhances but isn't required.
Minimal Training
If they can send a voice message, they can use LOGS. Real training time: 15 minutes.
Quick ROI
Most customers see measurable value within the first months. Often from a single prevented failure.