Your floor, to scale and alive.
A 3D model of your actual plant, every machine and bench where it really sits. Each one glows with running, paused, down or idle. Build it once and leave it on a wall TV.
The whole floor, lit by its status.
Place each machine where it stands and the plan becomes an andon board for the whole shop. Every linked machine carries a three-light stack, its asset code and today’s OEE, and takes one of the four states the asset board uses: running, paused, down or idle.
Four states, one mapping
Running is green, paused amber, down red and idle grey. The twin works out each machine’s state exactly as the asset board does, so the two never disagree.
A chip over every machine
Each linked machine carries a stack light, its asset code and its OEE so far today. From the View menu, labels can be full, compact or switched off.
The floor in one pill
A pill in the corner counts the linked machines by state, with the average OEE today and the number of zones. Hover it for the breakdown.
Select a machine. Read its day so far.
Real-time machine monitoring without leaving the map. Select any linked machine and its inspector shows the job loaded on it, today’s OEE in two-hour bars, its latest timer and downtime entries, the operator on station and any open downtime.
The job it is running
The step and job number of the newest job loaded at the workstation, such as Bend on J-4419, or No job loaded when the machine is empty.
OEE for today
Recorded-time OEE for the plant day: running time as a share of the running and downtime recorded, with twelve two-hour bars beneath it.
Who is on it, and what stopped it
The operator on station, the latest timer and downtime entries, and any open downtime with its reason and how long ago it began. Open work centre takes you to your assets in master data.
Nobody switches the andon on. The work does.
A digital andon that reads the workstation, not a sensor. Running the timer, pausing it with a reason and recording downtime on an idle machine already set its state in Production, so the map needs no wiring and no extra data entry.
Running
While the operator’s timer runs, the machine is running, and the person who started it shows as the operator on station.
Paused
Pausing the timer asks for a downtime reason, grouped as availability, performance or quality loss. The machine stays amber until work resumes.
Down
Downtime recorded on a machine with no timer running and no work loaded, such as planned maintenance, turns it red until the event is closed.
Zones that roll up their machines and 5S.
Draw a zone round a cell and it counts the machines inside it: how many are running and their average OEE today. Link the zone to an audit area and it also carries a live 5S audit score, the average of that area’s completed audits over the last 30 days.
A roll-up per cell
Each zone card shows how many of the linked machines inside it are running and their average OEE today, and the zone inspector lists them with their state.
5S from real audits
The score is the 30-day average of completed 5S audits for the linked audit area: green from 80%, amber from 60% and red below.
Honest when empty
A zone with no audit area says so, and an area with no completed audits in the window shows No completed 5S audits instead of a zero.
Lay out the floor as it stands.
Turn the factory floor plan into a working layout in the browser. Shape the floor slab on a grid, place machines and support items from a catalogue of 57 models, draw zones, walls, safety barriers and machine fencing, and turn any machine or item a quarter at a time.
57 models, two kinds
31 machines and stations, from CNC mills and presses to injection moulders and 3D printers, link to assets. 26 support pieces such as racks, pallets, docks and forklifts dress the floor and carry no data.
Walls, barriers and fences
Draw them along the grid, and add or cut away floor with the floor shape tool, so the model reads like the building. Anything placed turns a quarter at a time.
One floor, logged
Each site has one shared layout that every viewer sees. Edits apply for everyone at once, and each one is written to the activity log with who made it.
Link a shape to an asset and it comes alive.
A machine on the plan is only a shape until it is linked to one of your assets, the machines and work centres set up in master data. Search by name or code, pick one, and from then on the shape shows that asset’s state, OEE and job.
One asset, one machine
An asset can back only one machine on the floor. Assets already placed are marked placed, and linking one a second time is refused.
Active assets only
The picker lists your active assets. If an asset is later deactivated, its machine drops back to Not linked instead of showing stale numbers.
Change it any time
Unlink releases the asset and leaves the shape where it is. Every link and unlink is logged with the old and the new asset.
Put the floor on the wall. Leave it running.
A visual factory needs one screen the whole shop can read. Open the twin on a wall display, switch to fullscreen (TV mode) and choose Bird view for a flat plan or Live view for the angled floor. It keeps itself current, refreshing when production changes and every 30 seconds while it is on screen.
Live or Bird
Live view is the angled floor you can orbit and zoom. Bird view locks to a top-down plan that only pans and zooms, so a wall screen stays steady.
Only what reads from afar
The View menu sets machine labels to full, compact or off, and hides the zone labels, the floor grid or the legend and counters.
A screen that looks, never edits
Sign the display in with a view-only role such as the standard Dashboards role. Without the layout permission, Edit layout is not offered.
What a factory digital twin should show.
In manufacturing, a digital twin of the factory floor is a live model of the plant that shows where each machine stands and what it is doing now. Bulk answers each question from records the workstations and audits already write.
| The question | Where the answer comes from | Where you read it |
|---|---|---|
| Is this machine running? | The workstation: running while the timer runs, paused when it is paused with a reason, down when downtime is recorded with no timer running and no work loaded, idle otherwise. | Stack light, chip and status pill |
| How well has it run today? | Recorded-time OEE for the plant day, in twelve two-hour buckets. | Chip OEE and the inspector’s OEE progress |
| What is it working on? | The newest job loaded on the asset at the workstation: its step and job number. | Inspector, Current job |
| Who is on it? | The operator who started the timer at the station. | Inspector, Operator |
| Why did it stop, and when? | The open downtime event’s reason and start time, with the latest timer and downtime entries. | Inspector, Alerts and Latest timers |
| How is this area doing? | The linked machines inside the zone, plus the 30-day average of completed 5S audits for its audit area. | Zone card and zone inspector, from Audits |
| How is the whole floor doing? | Linked machines counted by state, the average OEE today and the number of zones. | Stats pill, and the Home tile, worst first |
| Who changed the layout? | Every placement, move, link, zone and wall change, with the person and the old and new values. | Activity log and the audit trail |
The twin reads the whole plant.
The Digital Twin installs on top of Production and stores only the layout. Its colours, jobs, OEE and 5S scores are read from the apps below, which is why the map and the plant agree.
- ProductionStation timers and pauses set each machine’s state and job.
- OEE & AnalyticsToday’s OEE and downtime reasons, from the same OEE records.
- AuditsCompleted 5S audits give each linked zone a 30-day score.
- Hub & HomeMachines link to your assets, and a Home tile opens the twin.
- DashboardsThe view-only Dashboards role can put the twin on a wall.
Questions, answered.
What is a digital twin of the factory floor?
A live model of your plant floor that shows each machine where it stands and what it is doing now. In Bulk it is a 3D floor in the browser: machines linked to your assets show their state, today’s OEE, the job loaded, the operator on station and any open downtime, and zones roll up the machines inside them.
Where does the live status come from? Do I need sensors?
From the workstation. A running timer makes a machine running, pausing it with a reason makes it paused, and downtime recorded on a machine with nothing running or loaded makes it down. No sensors, PLC connections or extra data entry are needed.
What do the colours mean?
Green is running, amber paused, red down and grey idle. The twin works out each machine’s state exactly as the asset board does, so the two views always agree.
Which OEE does the twin show?
Today’s recorded-time OEE for the plant day: running time as a share of the running and downtime recorded, with twelve two-hour bars in the inspector. It is today so far, not a history; trends live in OEE & Analytics.
How do I build the floor layout?
In Edit layout, shape the floor slab on a grid, place machines and support items from a catalogue of 57 models (31 machines and stations, 26 support pieces), draw zones, walls, barriers and fencing, and rotate items in quarter turns. Then link each machine to one of your assets from its inspector.
How is a zone’s 5S score worked out?
Link the zone to an audit area and it shows the average of that area’s completed 5S audits over the last 30 days: green from 80%, amber from 60% and red below. A zone without an audit area shows no score.
Can it run on a wall TV?
Yes. Open it in a browser on the display, switch to fullscreen (TV mode) and pick Bird view for a steady top-down plan. It refreshes when production changes and every 30 seconds while it is on screen.
Who can see it, and who can change it?
Viewing needs the View digital twin permission, which the standard Super user, Entity admin, Manager and Dashboards roles include. Editing needs Manage digital twin layout, held by Super user, Entity admin and Manager. Every layout change is logged with who made it.
Can I model more than one hall or site?
Each site in Bulk has its own floor, created as Factory floor the first time anyone opens the twin there. Within a site the twin manages one shared layout today.
Is the Digital Twin ready to use?
It is in beta. Viewing and editing the floor work today, and the app is still gaining capability, so some labels and behaviour may change between releases.
Is the twin a separate system?
No. It is an app installed on top of Production that reads Production, your asset list and, for 5S, Audits. Bulk runs from the customer order to the invoice on one record, installed one app at a time, and the twin is one view of it.
See your floor from above, live.
Start a free trial, lay out your machines and cells, and put your floor on the screen you want it on. No card needed.
