#1 AI Machine Monitoring Software for Manufacturing

Guidewheel's sensor clips around a machine's power conductor and reads its electrical heartbeat, so every machine you own turns into a live data stream on day one.
AI runs on top of it: always-on algorithms flag subtle deviations from a machine's normal performance pattern, and alerts reach the right person's phone while there is still time to act.
Any machine that uses power, whatever its age, make or model. No PLC, no MES, no data science team.

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

Get a Guidewheel demo and learn how to reduce downtime and increase production

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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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Where AI pays first

Before AI can predict anything,
it has to see everything.

48%

“48% of measured downtime sits in three under-instrumented categories (electrical, material, and staffing), more than 2x mechanical breakdowns combined.” A model trained on the mechanical signature is watching the smaller half. The same report puts it more bluntly: mechanical-first maintenance programs only fix one fifth of the problem. Guidewheel 2026 Factory Uptime Report, 75 million machine-minutes.

How a factory AI project usually gets scoped
  • It starts on the handful of assets someone already suspects, because that is where the budget for extra hardware goes.
  • The model wants failure history before it will say anything, so the first useful output is months away.
  • A data scientist or an integrator sits between the question and the answer, and neither of them is on the floor at 6am.
  • It is trained on the mechanical signature, so a two-hour wait for material never registers as a loss at all.
  • The pilot proves out on one line, and the business case for the other forty never gets written.
With Guidewheel
  • Every machine that uses power is in scope on day one, not just the ones already on a watch list. The sensor clips around the power conductor.
  • Anomaly detection runs on live data from all of them: it detects subtle deviations from normal performance patterns and surfaces potential issues that manual checks may miss.
  • The same data stream times every stop, so a material wait, a slow changeover and a late start show up as losses next to the mechanical ones.
  • Alerts route to the right person’s phone while the machine is still down, not into next week’s report.
  • Operators tag the reason in a few taps on a stop that is already recorded, so the why comes from the floor rather than from a model guessing at it.
  • No data science team. The algorithms are always on and ship with the platform, and dedicated onboarding and ongoing support come with every plan.

See every minute without an IT project, let AI do the Pareto, and catch drift before it’s downtime. That is the three-move playbook top-quartile plants run, in our own 2026 Factory Uptime Report. Move one is a sensor that clips on, 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

Does Guidewheel do predictive maintenance?

Not as we would define it, and we would rather say so than sell you one. Guidewheel reads every machine's power draw in real time, detects subtle deviations from that machine's normal performance patterns, and surfaces potential issues that manual checks may miss. What it does not do is model a specific component's remaining life. That distinction matters more than it sounds: our own 2026 Factory Uptime Report found that 48% of measured downtime sits in three under-instrumented categories (electrical, material, and staffing), more than 2x mechanical breakdowns combined, and that mechanical-first maintenance programs only fix one fifth of the problem. Coverage of every machine tends to pay before depth on a few.

What does the AI actually detect?

Abnormal machine behavior, judged against how that specific machine normally runs. Always-on algorithms detect subtle deviations from normal performance patterns, give early warnings of performance issues, and surface potential problems that manual checks may miss. Alongside that, the same signal gives you run, idle and down status live, the duration and reason for every downtime event, and a Pareto of your biggest drivers by machine, shift or type.

Do we need a data scientist, or an IT project, to run it?

No. The algorithms come with the platform and are on from the first day of data. There is no PLC integration, no per-machine controller to buy and nothing joins your controls network, because the sensor clips around the power conductor. You do not need existing infrastructure either: the sensors reach the cloud over ethernet, WiFi or LTE depending on what the site already has. Dedicated onboarding and ongoing support come with every plan.

What type of machines does Guidewheel work on?

Any machine that uses power, regardless of age, make or model. That is the part that matters for AI specifically: a thirty-year-old press with no controller to query gets the same live data stream and the same anomaly detection as a machine bought last year, because the sensor clips around the power conductor instead of connecting to your controls network.

How quickly can we start seeing data?

Most teams are up and running in a day, with visibility live within hours of sensor install.

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 put AI on machines you already own?

Let's talk about what always-on anomaly detection, real-time alerts and reason-coded downtime look like on your floor, on every machine that uses power. Bring your oldest one.

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