#1 Production Tracking Software

Guidewheel's sensor clips around a machine's power conductor and reads its electrical heartbeat, so every run, every stop and every cycle is recorded in real time.
Track production on any machine that uses power, whatever its age, make or model, and compare actual cycle times against your targets.
See where the shift stands while there is still time to act on it. No PLC, no MES, no IT project.

Run your lost-production 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 the number comes from

You already count production.
This is what changes.

48%

“48% of measured downtime sits in three under-instrumented categories (electrical, material, and staffing), more than 2x mechanical breakdowns combined.” A count sheet records that the shift came up 40 short. It never records which of those three took the hours. Guidewheel 2026 Factory Uptime Report, 75 million machine-minutes.

On the hourly count sheet
  • The tally gets written down when someone has a hand free, so the count ends up honest and late at the same time.
  • Actual against plan is assembled the next morning, about a shift nobody can go back and fix.
  • The sheet says you finished 40 short. It does not say which hours went missing.
  • A slow cycle and a fast cycle look identical on a form that only records totals.
  • The operator’s sheet and the ERP disagree, so the meeting starts by deciding whose number to trust.
  • By the time the report exists, the crew that ran the shift has gone home.
With Guidewheel
  • Run, idle and down come off the machine’s own power draw, all shift, without anyone writing anything down.
  • Planned against actual production is tracked live, and machine-specific OEE can go up on a display on the plant floor.
  • Cycles are tracked in real time and compared against your targets, so a slow cycle shows up as a slow cycle.
  • When the count is short, the same screen carries the stops, how long each one lasted, and the reason an operator tagged.
  • Pareto ranks the drivers by machine, shift or reason, so the meeting starts at the fix instead of at the arithmetic.
  • Every level reads the same number, from the operator’s screen to the plant manager’s dashboard.

The count stops being a job someone does at the end of the hour and becomes something the machine already reported. Guidewheel sits alongside the ERP you already run, 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

How does Guidewheel track production without anyone keying in a count?

The sensor clips around the machine's power conductor and reads its electrical heartbeat, so run, idle and down are recorded from the machine itself. Cycles are tracked in real time off that same signal, and you can compare actual cycle times against your targets. Nobody has to write a tally at the end of the hour for the record to exist.

Can we see actual against planned production while the shift is still running?

Yes. Guidewheel forecasts throughput and tracks planned versus actual production alongside uptime, OEE and cycle times, and machine-specific OEE can be displayed on the plant floor so the floor sees where the hour stands. That is the difference between a number you review tomorrow and a number you can still act on.

The shift came up short. Does Guidewheel show where the time went?

Yes. Every stop is timed from the moment the machine stops drawing power, operators tag the reason in a few taps on a stop that is already recorded for them, and Pareto ranks your top drivers by machine, shift or reason. The shortfall stops being a total and becomes a list you can work down.

Does Guidewheel track scrap and quality?

Operators record scrap reasons in Guidewheel in a few taps, and those reasons roll up with the rest of your production data. Guidewheel reads the machine rather than the part, so quality data comes from what your team records, against a machine record that already exists. Teams use it to cut scrap, but the sensor is not an inspection system and we do not present it as one.

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, with live machine data within hours of sensor install. 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 the shift while it is still running?

Let's talk about how Guidewheel turns run, idle, down and cycle data from your own machines into a production number your whole team can act on before the shift ends.

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