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Measure Every Process. Document It Automatically.
Video-based time studies that complete in hours instead of days. SOPs generated from production footage without an industrial engineer standing at the workstation. Real-time compliance monitoring that flags deviations before they compound.
The IE Bottleneck
A traditional time study takes 2 to 5 days per workstation. Most plants complete fewer than 20% of their planned studies in a given year. The backlog grows.
Cycle time assumptions age. Planning operates on stale data. SOP documentation follows a similar pattern. Creating a structured, accurate SOP from scratch takes weeks per process. Many processes simply go undocumented, leaving tribal knowledge as the operating system.
rocess compliance sits in a third gap. SOPs exist — when they exist — but verification depends on scheduled audits and floor walks. Between audits, deviations accumulate silently. By the time a non-conformance is traced back to process drift, the damage is already in production.
Industrial engineering capacity is finite. The work that depends on it is not. Process Vision changes the ratio.
Why This Matters
IE time studies take 2 to 5 days per workstation; most plants complete less than 20% of planned studies per year (IIE). Every undocumented process is a risk — inconsistent cycle times, unvalidated SOPs, and training gaps that compound with each new hire. The financial impact is substantial: planning models built on stale cycle time data produce infeasible schedules, leading to missed delivery commitments and excessive overtime. VA/NVA (value-added / non-value-added) analysis — the foundation of process improvement — requires accurate time study data. Without it, Lean initiatives target the wrong activities and improvement efforts produce disappointing results. For plants running 50 to 200 workstations, the IE capacity constraint means that the majority of processes operate without current documentation or validated cycle times.
How It Works
What Process Vision Does
Measurable Outcome
Recover IE Capacity
Time studies that consumed days now complete in hours. Your IE team focuses on improvement projects, not stopwatch exercises. For a typical mid-market plant, this recovers 30 to 50% of IE capacity — capacity that can be redirected to value stream mapping, process redesign, and kaizen facilitation.
Document the Undocumented
Processes that have run for years without formal SOPs get structured documentation — generated from video, not from memory. The SOP gap closes systematically rather than depending on IE availability. SOP coverage increases from the typical 30-50% of processes to near-complete documentation within months.
Continuous Compliance, Not Periodic Audits
Process deviations caught as they happen. The gap between "SOP exists" and "SOP is followed" closes from weeks to seconds. Process compliance becomes a continuous metric rather than a periodic audit score, enabling immediate coaching and correction.
Accurate Planning Inputs
Cycle time data flows from Process Vision into Asireon, ensuring production plans reflect actual floor performance — not assumptions from last quarter's study. When cycle times change due to process improvements, material changes, or workforce shifts, the planning system updates automatically.
Expected Outcomes:
In early deployments, time study completion rates have increased from less than 20% of planned studies to over 90%, eliminating the IE backlog.
SOP coverage has increased from 30-50% of processes to above 85% within the first six months of deployment.
Cycle time variability has decreased by 15-25% as continuous compliance monitoring catches and corrects process deviations in real time.
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See Process Vision on Your Floor
Book a consultation. We will walk through how Process Vision applies to your time study backlog, your SOP gaps, and your compliance requirements — and how video-based analysis changes what your IE team can accomplish. Bring your most complex workstation. We will show you what a study looks like in hours, not days.