Real-time digital andon system software for every machine on your floor

Guidewheel's sensor clips around a machine's power conductor and reads its electrical heartbeat, so a stop raises its own alert.
Live scoreboards for the floor, mobile alerts to the right person, and a few taps for operators to tag the reason or call for support.
Works on any machine that uses power, whatever its age, make or model. No PLC, no MES, no IT project.

Run your downtime numbers→ Free calculator, no email required
4.9 on Capterra
4.7 on G2

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Real-world results

What changed on their floor

Downtime calculator

What is your downtime actually worth?

Five numbers you already know. No email, no gate, no follow-up unless you ask for one.

Two shifts, five days is about 80. Three shifts, five days is 120.
Pre-filled with 54.5%, the weighted US average across 75 million machine-minutes in our 2026 Factory Uptime Report.
Contribution margin per hour, not revenue. This is the number that moves the answer most, so replace it with yours.

Lost production, at your numbers

-

a year, in hours your machines were scheduled to run and did not

Scheduled machine-hours a year-
Hours lost to downtime-
Per machine, per year-
What one point of uptime is worth-
Recovering those points is worth-
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What fires the signal

You already have a way to call for help.
This is what calls when nobody is standing there.

48%

48% of measured downtime sits in three under-instrumented categories (electrical, material, and staffing), more than 2x mechanical breakdowns combined. Those are the stops where nobody is necessarily standing at the machine to raise a call. Guidewheel 2026 Factory Uptime Report, 75 million machine-minutes.

On a stack light and a pull cord
  • The signal starts when somebody is there to start it. On a thin shift, or at 2am, that is the whole gap.
  • The light says a machine stopped. It cannot say why, how long, or whether the same thing happened on Tuesday.
  • It reaches the people who can see it from where they happen to be standing.
  • Escalation is one person walking over, then another person walking further.
  • Idling and slow running never trip anything, because nothing has technically stopped.
  • When the light goes out the event goes with it, so there is nothing to count at the end of the month.
With Guidewheel
  • The stop is the trigger. The sensor reads the machine’s power draw, so the signal fires whether or not anyone is at the machine.
  • Operators still raise it themselves: tag the downtime reason or request maintenance support in a few taps.
  • The alert goes to the right person on their phone, no matter where they are, on downtime, overloads or anomalies.
  • Scoreboards give the floor the live board, at machine and plant level, updating in real time across every shift.
  • Every stop is timed and logged, so Pareto ranks which problems keep coming back by machine, shift or reason.
  • Runs on any machine that uses power, whatever its age, make or model. No PLC and no per-machine controller to buy.

Fibrix Filtration’s VP of Operations, Juliana Sacharnoski, on what changed off-shift: “With Guidewheel, we now get notifications within an hour and a half when a line is down. Even if it’s the middle of the night, someone is going to react.” Keep the lights on the wall if the floor reads them. What changes is where the signal starts, and the sensor clips around the power conductor, so nothing joins your controls network. See it on your own machines →

WHY OPERATIONS TEAMS CHOOSE GUIDEWHEEL

Keep machines up and costs down

Respond faster to downtime

Get alerts and real-time visibility into downtime so your teams can respond quickly, without waiting on shift or weekly reports.

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Focus on your most costly issues

Zero in on your top downtime drivers by machine, shift, or issue type, and direct resources where they’ll have the biggest impact.

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Recover hidden downtime

Identify and eliminate costly delays like slow changeovers, late starts, and microstops, that add up over time.

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Lay the foundation for predictive action

Track downtime in real time today and be able to scale with AI, condition monitoring, and integrations to stay ahead of failures tomorrow.

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Respond faster to downtime
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REAL-WORLD RESULTS

92% uptime for a full year on Fibrix’s most critical line

Real-time visibility into downtime and machine performance through Guidewheel helped the Fibrix team resolve key issues, align their teams, and achieve over 90% uptime for an entire year on their most critical line.

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92%
UPTIME ACHIEVED ANNUALLY
It is a no-brainer as far as implementing Guidewheel in your facility. You will not regret using this system.
Software Features
Uptime View
Uptime View
Scoreboards
Mobile Alerts
Operator Dashboard
Pareto Analysis
AI-Powered Anomaly Detection

Uptime View

Monitor whether machines are running, idle, or down, and why. With real-time visibility into runtime, your teams can jump on issues before they impact production.

  • See live machine status from any device
  • Know duration and reason for all downtime events
  • Spot and resolve issues as they happen
See it in Action

Scoreboards

Get complete visibility into factory performance across every line, shift, and site. Guidewheel’s scoreboards surface key metrics in real time, so your teams can stay aligned, act fast, and stay on target.

  • Live dashboards with views at the machine and plant level
  • Updates in real time across all shifts
  • Display key metrics like runtime, OEE, and more
See it in Action
Scoreboards

Mobile Alerts

Ensure your teams are instantly notified when downtime, overloads, or anomalies occur, no matter where they are.

  • Detect downtime or performance drops in real time
  • Alert the right person instantly
  • Keep output steady across every shift
See it in Action

Operator Dashboard

Give operators the tools to flag downtime, log issues, and keep lines moving in real time.

  • Tag downtime events and request maintenance support in just a few taps
  • Record scrap reasons without slowing down production
  • Feed real-time insights from the floor directly into your team’s decision-making
See it in Action
Operator Dashboard

Pareto Analysis

Pinpoint and address your biggest downtime drivers to focus resources where they’ll have the most impact.

  • Identify top downtime drivers by machine or type
  • See which problems are costing you the most time
  • Prioritize improvements based on data, not assumptions
See it in Action

AI-Powered Anomaly Detection

Catch abnormal machine behavior before it leads to a major failure.

  • Detect subtle deviations from normal performance patterns
  • Surface potential issues that manual checks may miss
  • Take preventative action to avoid costly unplanned stops
See it in Action
AI-Powered Anomaly Detection
Guidewheel is so precise, up to the second. It gives us the visibility we need to make the right decisions in the short, medium, and long term. It’s really helped us to win.
FAQ

Frequently Asked Questions

Is Guidewheel an andon system?

It does the andon job in software. A stop signals itself the moment the machine stops drawing power, the alert reaches the right person on their phone wherever they are, live scoreboards show status at machine and plant level across every shift, and operators tag a downtime reason or request maintenance support in a few taps. What it is not is hardware. We do not sell stack lights, towers or pull cords, and Guidewheel runs alongside the ones already on your wall.

What triggers the alert, the machine or the operator?

Both, and that is the point. The sensor reads the machine's power draw, so a stop is timed and recorded the moment it happens, whether or not anyone is standing at the machine. Operators can also raise it themselves, tagging the downtime reason or requesting maintenance support in a few taps, on a stop that has already been recorded for them.

Who gets the alert?

The right person for the issue, on mobile, wherever they are. Alerts fire on downtime, overloads and anomalies, so a supervisor does not have to be within sight of a light tower to know a line is down. Fibrix Filtration's VP of Operations describes the off-shift change plainly: they now get notified when a line is down even in the middle of the night, so someone reacts.

What if operators do not tag the reason?

You still get the event. The sensor times every stop whether anyone tags it or not, so your totals and your Pareto by machine and shift are complete from the first day. Tagging adds the why on top of a record that already exists, which is why it tends to stick better than a call an operator has to originate from nothing.

What type of machines does Guidewheel work on?

Any machine that uses power, regardless of age, make or model. The sensor clips around the power conductor instead of connecting to your controls network, so there is no PLC integration and no per-machine controller to buy.

Do we install the sensors ourselves?

You do not have to. Our team can install Guidewheel for you, and most sites are running in about a day. Dedicated onboarding and ongoing support come with every plan, in person or virtual. You also do not need existing infrastructure: the sensors reach the cloud over ethernet, WiFi or LTE, depending on what the site already has.

Do we have to replace our MES or ERP?

No. Guidewheel sits alongside what you already run. It connects to ERP, CMMS and BI tools through native connectors or an open API, and the sensor clips around the power conductor rather than joining your controls network.

What does Guidewheel cost?

Pricing is published. It starts at $15,000 a year and includes your first 10 machines, with dedicated onboarding and ongoing support from our team, in person or virtual. You do not need existing infrastructure: the sensors reach the cloud over ethernet, WiFi or LTE, depending on what the site already has. No quote to chase, you can see the current figure on our pricing page before you ever speak to us.

Ready to see every stop signal itself?

Let's talk about how Guidewheel alerts the right person the moment a machine stops, puts live status in front of the floor, and gives operators a way to call for help in a few taps.

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