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The Product Overview

FixedPlantIQ is software designed specifically for monitoring and improving fixed plant performance.

It brings production, downtime, slow running, reliability, investigations and corrective actions together in one system, giving teams a connected view of plant performance and where improvement opportunities exist.

FixedPlantIQ uses data from existing plant systems to track production, detect downtime and slow running, measure lost operating time and identify recurring problems.

Significant events can be investigated through to root cause, with corrective actions assigned and tracked to completion, creating a permanent history of what happened and what was done about it.

FixedPlantIQ works alongside your existing plant systems without replacing your PLC, SCADA or historian infrastructure.

Software Modules

The Downtime Module

Identify where operating time is lost and why

  • Automatically detects downtime and slow-running events across the plant.
  • Records when each event starts and stops, its duration and the operating time lost.
  • Captures what happened and why using your plant's configured downtime and cause classifications.
  • Automatically calculates availability, utilisation, uptime, MTTF and MTTR.
  • Shows Pareto analysis, trends and event history so you can see the largest and recurring losses.
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The Production Module

Know exactly how your plant is performing against plan.

  • Automatically tracks actual production across configured plant areas and processes.
  • Compares actual production against budget, forecast and target.
  • Shows production variance so you can immediately see where performance is ahead or behind plan.
  • Tracks production performance by shift, day, month and longer operating periods.
  • Shows production trends and history so you can identify shortfalls, recurring losses and changes in plant performance.
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The 5 Why Module

Turn recurring problems into lasting corrective action

  • Automatically triggers a 5 Why investigation when configured criteria are met.
  • Provides a structured investigation process to work through each Why and identify the root cause.
  • Links the investigation directly to the operational event that triggered it.
  • Assigns and tracks corrective actions, owners, due dates and completion status.
  • Retains completed investigations, root causes and corrective actions so previous problems and solutions are not lost.
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The DataIQ Module

Turn plant performance data into clear improvement priorities

  • Presents MTTF, MTTR, availability, utilisation and uptime so equipment and reliability performance is immediately visible.
  • Shows downtime and slow-running Pareto analysis so you can see which losses are costing the most operating time.
  • Shows actual production against budget, forecast and target so you can immediately see where performance is off plan.
  • Shows recurring downtime, failures and performance losses over time so repeat problems are easier to identify.
  • Automatically generates and distributes configured performance reports for shift, daily, weekly and management reviews.
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The Configuration Module

Configure FixedPlantIQ around the way your plant operates

  • Build your actual plant structure, from site and plant areas down to the equipment and measurement points you want to monitor.
  • Set the production budgets, forecasts, targets and operating limits your plant measures performance against.
  • Configure downtime, slow-running, failure and cause classifications to match the terminology your operation already uses.
  • Set the rules that determine when events are created and when problems automatically trigger an investigation.
  • Control users, permissions and access so the right people can view, review, investigate and manage the information relevant to them.
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The Help Module

Give your team the answers they need to keep working

  • Provides an integrated Knowledge Base with practical guidance for using FixedPlantIQ and its modules.
  • Gives users clear step-by-step instructions for completing common tasks and system workflows.
  • Provides searchable help so users can quickly find answers without having to contact support.
  • Provides administrators with guidance for configuring, maintaining and managing FixedPlantIQ within the operation.
  • Directs users to FixedPlantIQ support when a software issue or question requires additional assistance.
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Software Modules

The 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.

     

USE CASES:

Used by maintenance teams to identify recurring failures and prioritize fixes

Reduce unplanned downtime by up to 30%
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Production Module

The Production Module captures real-time production data across the plant, providing clear visibility into output, throughput, and operational flow. It helps teams understand how production performs across shifts and where losses occur.

     

USE CASES:

Used by operations teams to monitor production output and optimise efficiency

Improve production visibility and maximise plant throughput
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The Downtime Module

The 5 Why Module enables structured root cause analysis by guiding teams through a step-by-step questioning process. It helps uncover the underlying causes of downtime and operational issues, ensuring problems are solved at their source.

     

USE CASES:

Used by maintenance and operations teams to investigate and eliminate recurring issues

Identify true root causes and prevent recurring failures
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The Data IQ Module

The Data IQ Module transforms raw plant data into meaningful insights by organising, analysing, and contextualising information from across the system. It enables better understanding of operational patterns and supports data-driven decision making.

     

USE CASES:

Used by analysts and managers to gain deeper insights into plant performance

Turn complex data into clear, actionable intelligence
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The Configuration Module

The Configuration Module allows teams to customise system settings, asset structures, and data inputs to match plant operations. It ensures the platform aligns with real-world processes and supports accurate data capture.

     

USE CASES:

Used by administrators to configure the system according to plant requirements

Adapt the platform to your plant’s unique operations
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The Help Module

The Help Module provides users with guidance, documentation, and support resources to navigate the platform effectively. It ensures teams can quickly find answers and make full use of system capabilities.

     

USE CASES:

Used by all users to access support and learn how to use the system efficiently

Empower teams with accessible support and guidance
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What Your Teams Can Do With FixedPlantIQ

Turn plant data into clear priorities, better decisions and measurable operational improvement.

01

Find the Problems

  • Biggest Operating Time Losses: Identify the biggest causes of lost operating time and focus improvement effort where it will have the greatest impact.
  • Least Reliable Assets:          Identify the least reliable assets using MTTF, MTTR, availability and failure history, then priortise reliability improvement work.
  • Production Performance Gaps: Identify which areas of the plant are consistently missing production budget, forecast or target and investigate why.
  • Recurring Operational Losses: Identify recurring downtime and slow-running problems instead of treating every event as an isolated occurrence.
02

Prioritise the Work

  • Where Time Is Being Lost: Identify the equipment, plant areas, event types and causes responsible for the greatest lost operating time.
  • Highest-Value Opportunities: Use Pareto analysis to separate the few high-impact problems from the hundreds of smaller events competing for attention.
  • Frequent Equipment Failures: Identify equipment that fails too frequently and focus reliability work on increasing the time between failures.
  • Excessive Repair Times: Identify equipment with excessive repair times and focus maintenance improvements on reducing time to repair.
03

Understand and Fix

  • Performance Patterns: Compare performance between shifts, days and longer periods to identify changes, patterns and recurring performance issues.
  • Production Shortfalls: Identify production shortfalls and focus operational attention on the areas driving the variance.
  • Root Causes: Investigate significant operational problems through to root cause instead of repeatedly treating the symptoms.
  • Corrective Actions: Track corrective actions through to completion and see whether recurring problems are actually being eliminated.
04

Run and Improve

  • Retain Operational Knowledge: Use previous events, investigations and root causes when the same or similar problems occur again.
  • Better Performance Meetings: Walk into shift, daily and weekly performance meetings with current plant performance and loss information already available.
  • One Operational Picture: Give Operations, Maintenance, Reliability and Metallurgy the same underlying picture of plant performance and priorities.
  • Measure Improvement: Measure whether operational and reliability improvements are actually increasing operating time, reliability and production performance.

Technical

Installation

  • Installed on-premise within the customer’s existing IT/OT environment.
  • Runs on a dedicated physical or virtual server.
  • Uses standard network connectivity to communicate with approved plant data sources.
  • Installation does not require changes to existing PLC, SCADA or historian applications.
  • No plant shutdown or interruption to existing control systems is required for installation.

User Access 

  • Access FixedPlantIQ from authorized computers across the plant network.
  • Multiple users can access the system simultaneously using concurrent licenses.
  • User access can support operations, maintenance, reliability, engineering and management teams.
  • Role-based permissions control what individual users can access and manage.
  • Reports and operational information can be automatically distributed to relevant personnel.

Cyber Security

  • Deployed on premises to keep operational data within the customer's environment.
  • Read-only plant-system connections prevent FixedPlantIQ from controlling plant equipment.
  • User authentication and permissions control system access.
  • FixedPlantIQ operates independently of plant control, so loss of the application does not stop plant operation.
  • Designed to operate within customer IT/OT network and cybersecurity requirements.

Architecture

  • Designed to operate within existing IT/OT infrastructure.
  • Connects to existing historians, PLCs, instrumentation and plant data sources.
  • Read-only integration with plant control systems.
  • No replacement of existing SCADA, historian or control systems required.
  • FixedPlantIQ operates as an operational intelligence layer alongside existing systems.

Deployment

  • Choose from three deployment options based on how much of the implementation you want FixedPlantIQ to manage.
  • Light: customer-led deployment with FixedPlantIQ providing guidance and support. Typically, 2–4 weeks.
  • Hybrid: shared deployment between your team and FixedPlantIQ. Typically, 4–6 weeks.
  • Turnkey: FixedPlantIQ-led deployment from scope and data collection through configuration, training and commissioning. Typically, 6–8 weeks.
  • Select the deployment option that best balances your internal resources, implementation support, timeframe and budget.
View FixedPlantIQ pricing and compare deployment options.

Configuration

  • Configure FixedPlantIQ around the way your plant actually operates.
  • Use your existing equipment names, plant hierarchy, terminology and operational structure.
  • Set different production targets, operating rules and performance measures for different areas of the plant.
  • Control what constitutes downtime, slow running and production loss for each measurement point.
  • Make configuration changes internally as the plant, equipment and operating requirements change.

System Requirements

  • Windows-based computers for users, typically located in control rooms, offices and engineering work areas.
  • A dedicated Windows server, either physical or virtual, to host FixedPlantIQ.
  • Microsoft SQL Server for FixedPlantIQ data storage and management.
  • Network connectivity between the FixedPlantIQ server, user computers and required plant data sources.
  • Access to existing plant data sources such as historians, PLCs, SCADA systems and instrumentation.

Support

  • Supported by experienced FixedPlantIQ engineers who understand both the software and fixed plant operations.
  • Simply log a Service Desk ticket and our support team will respond and work with you to resolve the issue.
  • Software performance and functionality issues are investigated directly by our technical team.
  • Built-in Help & Knowledge Base gives users immediate access to practical how-to guidance whenever they need it.
  • Software updates, fixes and new product enhancements are made available for your installation as they are released.

Ready to Unlock More From Your Existing Plant?

See how FixedPlantIQ can identify your biggest production losses, recurring problems and opportunities to improve plant performance.
Book a Demo
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