Productivity Management System (PMS)
For every manufacturer, productivity looks different. What’s essential is recognizing that these goals are interconnected and can amplify one another when supported by the right technology. By combining Advanced Analytics, contextualized data, and decision intelligence based on Industrial AI platform, Braincube helps manufacturers build a connected ecosystem where greater productivity, lower waste, and efficient energy use become aligned drivers of operational excellence—not isolated initiatives.
Identify and leverage these interdependencies with the Braincube Productivity Management System (PMS).
Value Proposition
Real-Time Productivity Gains
Efficiency improvement
Waste reduction possible
Fast ROI Achievement
Return on investment
WEMEQ Model
Reduce Waste
Eliminate products that cannot reach market. This includes scrap generation, yield losses, inherent production waste, off-specification output, overproduction runs, rework cycles, and excessive quality specifications that exceed customer requirements.
Reduce Energy Costs
Minimize utilities consumed throughout the production process. Address energy consumption patterns, carbon footprint reduction (ESG compliance), and identify high-consumption operations that conflict with sustainability mandates.
Reduce Material Consumption
Optimize raw material and process aid usage, ensuring quantities do not exceed what is necessary to produce saleable finished goods. Focus on raw material volumes, adhesives, coatings, chemicals, additives, and processing aids.
Optimize Line Efficiency
Eliminate nonproductive time and capacity loss—periods when equipment cannot generate saleable output. Improve OEE (Overall Equipment Effectiveness), production speed, asset availability, and eliminate unplanned downtime, stoppages, and process disruptions.
Improve Product Quality
Enhance final product performance or reduce production cost. Optimize product characteristics and finished goods specifications to exceed customer expectations and reduce quality-related complaints while enabling value-added product enhancements.
Key Technologies
DataOps Foundation
Braincube AI Platform integrates with existing IoT, SCADA, MES, Historian, and operational systems without requiring replacement. Real-time streaming data flows instantly, delivering actionable process insights while maintaining your current infrastructure investment.
Product Clones
Creates a digital replica of production conditions for every finished product—tracking thousands of variables from raw materials to finished goods. This enables replication of best practices and rapid root cause analysis of quality issues.
Discover Hidden Opportunities with CrossRank AI
Ranks process variables by business impact. Generates prescriptive recommendations for optimal settings. Completes root cause analysis in minutes instead of days. Automatically eliminates anomalies and erroneous data.
Digital Assistants
Role-specific guidance for every operator, engineer, and manager
• Operators: Real-time instructions and deviation alerts
• Process Engineers: Detailed metrics and analytical tools
• Plant and Corporate Management: Strategic dashboards with real-time KPIs
Case Studies
Discover businesses we’ve already helped
Global Tire Manufacturer
Challenge: Aging machinery, fragmented data, production downtime $1M annual savings 35% waste reduction 90% faster data analysis, Deployed across 60+ plants in 4 years. Braincube is key infrastructure for our organization’s future. The platform helped us completely transform how we use data.
Maple Leaf Foods-meat producer
Challenge: Productivity improvements, operational excellence, waste reduction, yield increase 10–12% gross profit increase through waste reduction, ROI achieved in 3 months (fastest across all case studies) Leveraged existing AVEVA MES + SCADA systems—no new IoT required“(…) guys are always tweaking the recipe at the start of a shift based on what Braincube gives them, which gives them an incredible golden batch each and every time.”- Andy Thorne, Senior solutions architect, Maple Leaf Foods
Building Materials Manufacturer
Challenge: Variance minimization, recipe optimization, $200k+ annual savings from one recipe change, Analysis time reduced from weeks to minutes.
Norske Skog Golbey – newsprint paper factory
Challenge: Sheet breaks halted production 7 times daily, costing $2,000 per incident, ~2 hours downtime daily $1.2M saved through reducing breaks to 2 per day, $4M+ additional savings achieved, $40M increased sales through 12% production cadence increase while reducing costs. New set points identified to eliminate 6.5 breaks daily.
International Paper – paper producer
Challenge: Productivity improvements, operational excellence, waste reduction, yield consistency, reduced process variability for stable high-quality output and minimal waste, 80% of facilities preparing to company-wide implementation. “Braincube’s Digital Assistants are like a smartphone for operations—operators receive ready-made recommendations and experiment quickly instead of waiting for IT. It changes everything.”- Andrew Jones, Senior Engineer Fellow
Integration with IT Ecosystem
Braincube provides full flexibility of deployment, allowing installation: On-premise, on Edge devices, and in the Cloud. This enables adaptation to diverse needs and production infrastructure.
ERP Integration – ERP integration allows Braincube to leverage critical business data such as orders, costs, and material availability, which translates into production process optimization and better resource management.
MES Integration – Braincube’s advanced analytics enhance MES capabilities by transforming collected data into intelligent analysis and recommendations. MES controls production, while Braincube provides the knowledge necessary for its continuous improvement.
SCADA/Historian Integration – The Braincube AI platform connects directly, retrieving real-time data and adding context. This enables in-depth monitoring and faster decision-making based on current information.
FAQ
Braincube is an AI-powered and machine learning-driven Productivity Management System. The platform analyzes historical and contextual production data to identify improvement areas, predict potential disruptions, and support data-driven decision-making. Braincube transforms raw operational data into actionable business intelligence.
Braincube addresses five main productivity areas:
• Waste reduction (scrap, off-spec production)
• Energy cost reduction
• Material consumption reduction
• Production line efficiency optimization
• Product quality improvement
Potential savings depend on your industry and production processes. On average, 25% of production costs are pure waste, while standard productivity targets are 3-5% annually. For example, one of our customers achieved $40M in savings through transformation, including $1.2M from production break reduction alone.
No. Braincube works as an integration system, utilizing data already generated by existing systems such as MES, Historian, SCADA, and other OT platforms. You don’t need to replace your entire infrastructure—Braincube integrates with it.
Implementation time depends on project scope and process complexity. Typically, we start with a pilot on one production line and then scale the solution to other areas. This process can take from several weeks to several months, depending on your goals.
Optimization means doing better work within known constraints. Transformation means breaking through those constraints and achieving significantly better results at scale. Braincube supports transformation by identifying hidden opportunities that traditional approaches cannot discover.
The system analyzes production data in real-time to find anomalies and patterns. It uses AI to automatically compare actual performance against optimal benchmarks. This reveals both visible waste (scrap) and hidden inefficiencies in your processes.
Braincube is optimized for continuous and semi-continuous production in sectors such as paper, energy, chemicals, food and beverages, pharmaceuticals, textiles, and other manufacturing industries requiring data-driven process optimization.
Braincube offers three key components:
• Product Clone – a digital replica of your production processes
• CrossRank AI – an AI engine for identifying optimal production settings
• Digital Assistant – an assistant supporting transformation and solution scaling
Yes. Braincube is designed to work with MES systems such as AVEVA, Siemens, Dassault Systèmes, and others. Integration allows full utilization of MES data to optimize production.
Companies typically see first measurable results within 3-6 months of implementing the pilot. Full transformation and scaling can deliver long-term savings reaching millions of dollars within 1-2 years.