The Challenge
Machines live with Guidewheel in two days
Machines fully deployed in one month
“Real-time visibility gives me eyes on the plant 24/7. I don’t have to ask three different people what’s happening—I already know.”
- Tyler Zeman, Production Supervisor
Seacast, a leading aerospace-grade casting manufacturer, needed better insight into machine utilization to improve efficiency. The team relied on manual production cards and tracking to monitor capacity, labor utilization, and throughput—but the process was slow, error-prone, and almost always a day behind.
Without real-time data, they struggled to understand true machine utilization and identify bottlenecks. Production delays and inefficiencies meant Seacast often needed to outsource some of their core production that could cost around $40K per month, simply because they didn’t have the data to figure out how to increase their in-house capacity. They needed a solution that could provide instant insights and drive data-backed decisions.
The Solution
From installation to impact in under a month
When Seacast discovered Guidewheel, they saw an opportunity to eliminate manual tracking and access real-time data. During the onsite training, the Guidewheel team installed 10 machines in just two days and trained the Seacast maintenance team on installation best practices. The team quickly took ownership of the process and brought the remaining 21 machines online in 12 days.
With 30 machines– including presses, x-rays, lathes, welders– fully deployed in under a month, Seacast unlocked immediate visibility into performance—without the cost or complexity of traditional manufacturing software. Within a month, they were able to see real-time machine data and started figuring out how to improve their processes.
“Installation was very easy as soon as we decided where to plug in the sensor. Other solutions required coding and reprogramming, Guidewheel was ready to go.” - Zeman
Tracking setup times and performance to increase capacity
With Guidewheel’s real-time insights, Zeman now has a clear, data-driven view of setup times– a critical bottleneck that they previously had limited visibility into. By identifying inefficiencies in the startup process and setting clear goals, they can unlock additional capacity from their existing assets.
Using the Scoreboard, the team can instantly see which machines are running, idle, or down, enabling faster, on-the-floor decision making. Supervisors use real-time alerts to quickly address issues before they escalate, while Zeman is tracking setup times as a key opportunity to increase availability and overall capacity.
By eliminating manual tracking and improving visibility, Seacast plans to streamline processes, increase output, and reduce reliance on costly, outsourced work.
“The Scoreboard has been a game-changer. It’s driven friendly competition and helped us find ways to improve setup times and daily output.” – Zeman
What Worked
For manufacturers looking to improve efficiency, here are Zeman’s top three takeaways:
1. Eliminate human error: replacing manual tracking with real-time machine data enables faster and more data-driven decisions
2. Streamline data collection: a single source of truth simplifies keeps teams aligned and simplified performance tracking
3. Take it step by step: define key metrics first, then gradually expand insights to drive continuous improvement
“Guidewheel is bringing Seacast into the 21st century. It’s a game-changer for production efficiency, quality, and even getting our customers excited about the visibility we now have.” - Zeman
