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The Problem: What Got You Here Won't Get You There
Legacy OEE Vorne boards are a great first step. They show you what's happening on a single line. But when you need to see across plants, layer on other key metrics, or build intelligence on top of your data, the box hits a wall.
- Enterprise decisions on a patchworkEvery plant runs its own way. No single view of capacity, performance, or cost across the operation. You're allocating capital based on incomplete data.
- No action layerYou can see utilization. But who's assigning corrective actions? Who's tracking whether the fix worked? The gap isn't data. It's what happens next.
- No intelligence layerA legacy board tells you what happened. It doesn't tell you what's about to happen.
- Integration gapGetting data out of the box and into your ERP, Power BI, or your data lake requires custom work every time.
If Vorne is asking you to buy a new generation of devices to keep getting software updates and your data doesn't carry over, and every unit needs to be reconfigured from scratch, that's the moment to ask whether the legacy model still makes sense.
Seeing the problem was the first step. Fixing it, proving it, and scaling it is the next one.
The Upgrade: What Changes with Guidewheel
One platform. Every machine. Energy, OEE, and AI in a single install.
- 2.5 minutes per machine — Clip-on sensor reads the electrical heartbeat. No PLC access, no wiring, no downtime. The oldest machine we've connected was built in 1935.
- Energy data comes free — You came for productivity. Energy data comes from the same sensor at no extra effort. kWh per machine, per shift, per plant. Hand your sustainability team a win you didn't have to work for.
- Cloud-native, enterprise-scale — One source of truth, flexible enough for every level. Operators get their line. Managers get the plant. Leadership gets the portfolio. Not 500 legacy units to manage.
- Integrates with what you already run — Built-in integrations with SAP, AVEVA / OSIsoft Pi, and most established platforms. API-first, so your data flows where you need it.
- Air-gapped cybersecurity — No connection to your OT network. No open ports on the factory floor. No PLC access required. Air-gapped by design, so your production data never touches the same network as your machines. Reduced attack surface. Your IT and security team will thank you.
- StateSense AI — Anomaly detection, pattern recognition, predictive insights. Not just a red/yellow/green light.
- Operators see it too — Real-time dashboards on floor TVs, tablets, and phones. Your operators get live visibility into their line. Your managers get the enterprise view. Same data, right level of detail.
Head to Head: How It Compares
A side-by-side look at what changes when you move from legacy OEE boards to a cloud-native platform.
| Guidewheel | Vorne / Legacy OEE Board | |
|---|---|---|
| Installation | ✓2.5 min clip-on per machine | —Hours of wiring per line |
| Energy monitoring | ✓kWh, cost, and emissions | —None |
| Can it predict problems? | ✓StateSense AI catches anomalies before they stop the line | —Shows what already happened |
| Multi-plant visibility | ✓One source of truth, flexible dashboards at every level | —Per-line boards, complex aggregation |
| ERP integration | ✓SAP, AVEVA / OSIsoft Pi, and most platforms. API-first. | —Custom integration required |
| Cybersecurity | ✓Air-gapped. No OT network access, no open ports, no PLC connection. Reduced attack surface by design. | —Runs an unencrypted web server (HTTP) on your plant network. PLC integration bridges OT and IT. No published security certifications. V1 devices run frozen software with no future patches. |
| Does the platform get smarter? | ✓Continuous updates, every customer benefits immediately | —Intelligence is locked to the generation you bought |
| Total cost at 100 lines | ✓One subscription. Every machine. No legacy units to buy, replace, or reconfigure. | —$500K-$750K+ in legacy boards alone, plus install labor, plus integration, plus upgrade cycles |
| Investment in R&D | ✓$52M+ from the world's top investors (BlackRock and Temasek's Decarbonization Partners Fund, Greycroft). Deep pockets to scale fast. |
From Box to Platform: How It Works
Four steps. No IT project. No months of planning.
1
Clip On
Sensor clips onto the power cable. Any machine, any age. The oldest we've connected was built in 1935.
2
Read the Heartbeat
Every machine uses electricity. That's the universal language. Running, stopped, idling, cycling, abnormal. Then layer on counts, temperature, pulse, pressure, whatever matters to your process.
3
See Everything
Real-time dashboard across every machine. Downtime, utilization, energy, OEE. One view for the floor, one for the enterprise.
4
Intelligence Flows
StateSense AI detects anomalies. Data flows into your ERP, AVEVA / OSIsoft Pi, Power BI, your data lake. Your team builds on top via API.
400+
manufacturers
5
continents
1.4X
avg productivity gain
2.5 min
per machine install
What You Unlock
The legacy board showed you what happened. Guidewheel shows you what to do.
Every machine, every plant, one dashboard
Stop stitching together data from separate legacy units. See your entire operation in one view.
Spot problems before they become downtime
StateSense AI detects anomalies in the electrical heartbeat. Catch issues before they stop the line.
Benchmark performance across sites
Compare shifts, lines, and plants against each other. Find your best performers and replicate what they do.
Run year-end reviews and org-wide analyses
Pull up any facility, any time range. See exactly where days of production were lost, which machines need replacing, and what the payback period looks like.
Know your true capacity and cost
Not estimated. Measured. Real-time utilization and energy data from every machine. Apply a cost to time savings and give your CFO numbers they can trust.
Cut energy waste with real kWh data
See which machines consume the most energy, when, and why. Hit sustainability targets with data, not guesswork.
Your team builds on top
Download Issues Analysis reports. Create custom tags and coding systems. Track corrective actions week over week. The data is yours to use however your operation needs it.
Renegotiate contracts with real numbers
Show exactly how much production time a customer takes versus the revenue they bring in. Turn machine truth into better deals.
"I give Guidewheel a 10/10. It's the first 'plug-and-play' solution that actually works for any machine on the floor." — Scott Coffey, Automated Solutions
The Proof
This is what happens when the foundation is right.
400+
manufacturers
1.4X
average productivity gain
35%
productivity improvement at J&J
15-20%
energy cost reduction
"I give Guidewheel a 10/10 because it's the first 'plug-and-play' solution that actually works for any machine on the floor. Within days, we went from guessing why machines were down to real-time visibility into our bottlenecks."
— Scott Coffey, Automated Solutions
"I love this setup style. 40 minutes to get the whole thing set up with sensors. That is beautiful."
— Director of Vehicles Assembly Plant, General Motors
"I check Guidewheel every morning, even before my prayers."
— VP Operations, $2B packaging company
Backed by: BlackRock and Temasek's Decarbonization Partners Fund, Greycroft
Trusted by: Johnson & Johnson, Hershey, General Motors, U.S. Steel, Georgia-Pacific, Godrej, Igloo, Steelcase, Land O'Lakes, Pelican, Cargill, Luxottica, GE Aerospace
Why Now
Teams typically make the move when...
Legacy upgrade cycle hits
Vorne is asking you to buy a new generation of devices. New boards, new configuration, data doesn't port. If you're going to start over, start on a platform that won't ask you to do this again.
The plant count doubled
An acquisition, a new facility, an expansion into new markets. The per-line legacy model that worked at 10 plants breaks at 40.
The board wants enterprise visibility
They're asking about capacity across the portfolio. Sustainability reporting. Capital allocation based on real data. A patchwork of legacy boards can't answer those questions.
ERP modernization is underway
You're migrating to S/4HANA or upgrading your data stack. This is the natural moment to connect your machines to the rest of the business.
The Upgrade Path: Crawl, Walk, Run
You don't have to flip a switch. Start small, prove the value, then scale.
1
Crawl
Start with one line or one plant. Prove the value in days, not months.
2
Walk
Expand across the facility. Compare shifts, lines, machines. Build the business case with real data.
3
Run
Enterprise rollout. Every plant, every machine, one platform. ERP integration. AI-powered insights at scale.
You don't have to rip and replace. Start alongside your existing system. Let the data speak.
Upgrading from legacy OEE boards? Ask about our special package for teams making the switch to Guidewheel.
How Things Look Different with Guidewheel
The platform is only as good as the actions it drives. Here's what real teams are doing with Guidewheel, right now.
Weekly downtime accountability
Every week, plant managers review their top downtime drivers with operators and assign corrective actions together. They track what's working and what's not. It's become the rhythm that turns data into results.
Tying production data to commercial decisions
Teams use tags and coding systems to track exactly how much production time each customer takes. One team found a customer using 45% of their capacity but representing only 25% of revenue. They renegotiated, won 75% of that customer's business, and now apply that lens across their whole book.
Small fixes, measurable impact
One team spotted late starts tied to break overruns. Fix: a two-minute warning buzzer. Late starts dropped 32% in two weeks. That's the pattern. Spot the issue in the data, make a targeted change, see whether it worked. Repeat.
Building the case with real numbers
A head of maintenance runs year-end reviews in Guidewheel. At one facility, the data showed 187 days of lost production from staffing gaps on forming alone. One extruder built in 1989 accounted for 25 of 53 downtime days. That's how you build a payback case that finance signs off on.
Catching what no one could see
A mold box keeps requiring cleaning on the same line. The team sees the same tag showing up five, six times in Guidewheel. They pull the mold box, find a blown-out air cylinder, replace it. Problem gone. These are the issues that persist for months when all you have is a legacy OEE board.
Guidewheel at its best: identify a problem, make a small targeted change, see the impact in the data.
See It on Your Machines
7-day pilot. Real data from your floor. Nothing to buy, no IT project to scope. Just clip on and see what your machines are telling you.
✓
Any Machine
✓
400+ Manufacturers
✓
ERP & Platform Integrations
✓
Cybersecurity De-Risked
Contact: info@guidewheel.com
