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Built For Fixed Plant Environments

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 FixedPlantIQ is developed by engineers with hands-on experience in mining and process plant operations. 

Product Overview

FixedPlantIQ is an operational intelligence platform designed to support practical performance improvement in process plants.

The platform addresses a common challenge in plant operations: the lack of consistent, structured visibility into asset performance, downtime and production, even though most of the required data already exists within plant systems.

FixedPlantIQ transforms this operational data into clear, reliable insight, enabling teams to understand plant performance, identify production loss and investigate the true causes of operational issues.

Rather than introducing additional complexity or replacing existing systems, FixedPlantIQ works alongside current plant infrastructure, providing a structured layer of analysis and intelligence that helps operations, maintenance and leadership teams make better decisions and drive continuous improvement.

Core Platform Capabilities

High-level explanation of what the system enables.

Production Performance Measurement

Measure plant performance against forecast, budget and target capacity. Track utilization, uptime and production trends to understand how the plant is performing over time.

Downtime & Loss Analysis

Capture downtime and slow running events using structured classifications that provide deeper insight into production loss.

Root Cause Investigation

Integrated 5 Why investigations linked directly to operational events ensure the true causes of issues are identified and actions are tracked.

Operational Intelligence

Dashboards, Pareto analysis and performance trends transform operational data into clear, actionable intelligence.

What Problems FixedPlantIQ Solves?

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Core System Behaviour

Once configured, the system connecting to plant networks to monitor asset and process performance against defined targets.

  • Understand where and why performance loss.

  • Identify recurring downtime and slow-running conditions.

  • Track production performance across shifts and longer timeframes.

  • Support structured root cause analysis and signals.

  • Provide consistent reporting across management levels.

Software Modules

FixedPlantIQ is built around six integrated modules that work together to capture plant performance, analyse operational loss and support continuous improvement.

Each module focuses on a specific aspect of plant operations while sharing a common data structure that allows information to flow consistently across the platform. This enables teams to move from performance measurement, to analysis, to investigation and improvement within a single system.

Downtime Module

The Downtime Module captures and analyses downtime and slow running events, providing clear visibility of production loss across the plant. Operational events are recorded using structured classifications, allowing teams to understand when downtime occurs and the underlying causes behind each event.

Built-in Pareto analysis, event timelines and performance trends help identify the most significant sources of operational loss, enabling teams to focus improvement efforts where they deliver the greatest impact.

By linking events with investigation workflows, the module supports a structured approach to analysing and reducing downtime, helping operations and maintenance teams improve reliability, availability and overall plant performance.

Production Module

The Production Module measures plant production performance and provides a clear view of how operations are performing against targets. Production can be tracked against forecast, budget and target capacity, with traffic-light indicators highlighting when performance moves outside expected ranges.

Teams can monitor utilisation, uptime and month-to-date production trends, investigate periods of poor performance and understand the factors affecting throughput. Live dashboards, graphs and performance trends provide clear operational visibility.

Users can also add notes and annotations to explain performance changes. All production values include full audit traceability, capturing who made updates, when changes occurred and why they were required, ensuring transparency and accountability in operational reporting.

5 Why Module

The 5 Why Module provides a structured process for investigating operational issues and identifying the true causes of performance loss. Investigations can be triggered directly from downtime or production events, ensuring issues are analysed while operational context is still clear.

The investigation framework guides teams through a structured root cause analysis process, helping them move beyond symptoms to identify the underlying causes of operational disruption. Actions resulting from investigations can be recorded and tracked, ensuring accountability and enabling teams to monitor the progress of improvement initiatives. This structured approach supports consistent problem solving and helps drive sustainable operational improvement across the plant.

Data IQ Module

The Data IQ Module transforms plant data into operational intelligence that supports informed decision making. Data from multiple sources can be consolidated and analysed through interactive dashboards, reports and pivot table analysis, providing clear visibility of plant performance.

Users can build customised reports and visualisations to explore trends, compare performance across time periods and identify operational patterns. Insights can be shared across the organisation through scheduled reports and automated email distribution, ensuring that key performance information reaches the right people at the right time. This enables teams to turn plant data into clear insights that support performance monitoring and continuous improvement.

Configuration Module

The Configuration Module provides the flexibility to align the platform with the specific structure and operational requirements of each plant. Users can configure event classifications, production structures, plant areas and operational parameters to match how their operation functions.

This flexibility allows organisations to maintain direct control of system configuration, enabling the platform to evolve as operational requirements change without relying on external specialists. The configuration framework ensures the system remains structured, scalable and aligned with plant processes, supporting long-term use while allowing sites to adapt classifications, structures and settings as operations develop.

Help Module

The Help Module provides quick access to support resources directly within the platform.

Users can access the Knowledge Base, guidance materials and user documentation, allowing teams to resolve questions and understand system functionality without leaving the application.

The module supports both new and experienced users by providing clear explanations, practical guidance and access to assistance when required.

This ensures teams can confidently use the system and maximise the value of the platform in daily operations.

How Does FixedPlantIQ Work?

FixedPlantIQ is installed within the plant OT network and connects to existing data sources such as historians, PLCs or other plant systems. The platform uses this operational data to build a structured view of plant performance without replacing existing control or monitoring systems.

Operational data from these sources feeds into the Downtime and Production Modules, where events and production performance are captured and classified using site-defined configurations such as asset structures, event classifications and production parameters. This ensures the system reflects how the plant actually operates.

When events meet predefined criteria, investigations can be triggered within the 5 Why Module, allowing teams to analyse issues and identify root causes while operational context is still clear.

Captured data is then available through dashboards, trends, Pareto analysis and reports, with insights able to be automatically distributed via scheduled email reports to ensure the right people receive performance information when they need it.

Technical

Designed by Fixed Plant People

FixedPlantIQ was designed by a Process Plant and Maintenance Manager, and developed by engineers with experience across mining and heavy industry environments.

This background shapes every aspect of the product:

  • A focus on reliability and stability over novelty
  • Practical workflows that reflect how sites actually operate
  • Clear separation between monitoring, investigation, and improvement
  • Respect for existing OT, IT, and operational standards

The result is software that feels familiar to plant teams and fits naturally into day-to-day operations.

On Prem Deployment

FixedPlantIQ is specifically designed for:

  • Brownfield sites
  • Live production environments
  • Operations where downtime, reliability, and production matter

The system:

  • Deploys on-premise within the OT network
  • Connects to existing historians, PLCs, and instrumentation
  • Operates in a read-only manner with no interference to control systems

Security, stability, and operational continuity are treated as baseline requirements, not optional features.

Improvement Focused

FixedPlantIQ is not a black-box optimisation tool and does not attempt to automate decision-making.

Instead, it provides:

  • Clear visibility of what is happening
  • Consistent capture of performance events
  • Structured investigation using proven engineering methods
  • Reliable reporting across operational and management levels

This approach supports sustainable improvement driven by plant teams, rather than reliance on external consultants or opaque algorithms.

Customer Support Mindset

FixedPlantIQ is designed to be supported, configured and maintained over the long term.

Instead, the platform provides:

  • Site configuration control through the Configuration Module
  • Help desk support when technical or operational assistance is required
  • Knowledge Base access with practical guidance and documentation
  • Ask-a-question support for quick answers to common “how-to” tasks

This approach ensures organizations retain control of system configuration and operation, while still having reliable support and guidance available when needed.

Interested in seeing how FixedPlantIQ would work at your site?

Book a Demo