Decide4Action is a production monitoring and quality platform for high-speed beverage lines — real-time OEE and downtime, inline label and date-code verification, and QA, lab and batch data in one auditable system. Built for high-speed fillers, constant SKU changeovers, and the micro-stops, fill levels and date codes you can't afford to get wrong.
Five focus areas for beverage bottling and filling lines. Each stands on its own; all run on one platform, sharing the same data and reporting.
Measure OEE, output, rates and downtime live — from a single reference counter per line, up to full PLC supervision of multiple machines.
Connect directly to PLCs and field signals to pull filler and line states, speeds, counts and fault codes — no manual entry to know what the line is doing.
Filler and line stops are detected automatically; operators only qualify a cause when it can't be derived from the signals.
Live OEE, filler speed, cans and bottles per minute and current downtime, per machine and per line.
Pareto by line, filler, seamer or cause, with drill-down to event lists carrying timestamps, operator notes and PLC data.
Cases and pallets hour by hour with context — see when performance dropped, and why.
Period reports by line, crew, product family or area — no spreadsheet assembly.
A wrong label, missing date code or bad component isn't just a quality slip — it's a compliance risk. Verification catches it on the line, not at the retailer.
Confirm the right ingredients and quantities against the active recipe before anything runs.
Scan labels, trays, cartons and cases before startup; lot numbers captured automatically.
Cameras verify the label inline — automatic machine stop on a wrong or missing label.
A vision camera reads the date code inline — automatic line stop on a fault.
Startup and hourly checks go digital — print, colour, legibility — timestamped, with photo evidence.
Every packaging lot tied to the order record; trace a lot or batch in seconds.
Enforce consistent specs across shifts, trend Brix, CO₂ and fill weight over time, and respond instantly during a hold or recall — with a complete audit trail.
Brix, CO₂, fill height, net content and pH entered against built-in ranges, flagged the moment they're out of spec.
Carbonation and fill-height drift surface mid-run — proactive, not after the pallet ships.
Startup, hourly and end-of-run QC checks run to a set schedule — carbonation, fill, torque and seal.
Structured holds with case counts and approval routing; print hold tags so the pallet matches the digital record exactly.
Every entry, edit and approval logged with timestamp and user — audit-ready for SQF and BRC.
Guided syrup-room and blend recordkeeping: what was measured, corrected, and the outcome.
Replace paper checks and manual sign-offs with structured digital forms — then route, notify, validate and approve automatically, with full traceability.
Build any operator form — pre-op, CIP / sanitation, seamer teardown, changeover — with custom fields, photos and sign-offs.
Forms route to the right person automatically; no chasing paper across shift handover.
Workflows make sure periodic checks happen on time, at the expected frequency — logged with who signed off and when.
A non-conforming check or out-of-range CIP alerts quality or maintenance automatically — before it becomes a hold.
Step-by-step guided instructions, with video, right at the task — onboard new hires and log who completed each procedure, and when.
Every completed form stored centrally and searchable by date, line, SKU or shift.
A secure top layer over the meters, sensors and controls you already have — see where energy, water and CO₂ are wasted, benchmark line to line and site to site, and catch asset wear before it stops the line.
Correlate kWh with output to expose idle loads and off-shift waste — benchmarked per case, line and equipment.
Litres per case and reuse ratio by process; catch leaks and continuous flow during downtime.
Monitor CO₂ and ammonia compressor loads and efficiency — uptime, safety and greenhouse-gas intensity.
Flow, pressure and leakage analytics expose unbalanced loads and high-demand assets on blowers and air conveyors.
Vibration and temperature on critical assets reveal condition and predict failures — fewer stoppages, longer asset life.
A secure top layer onto existing PLCs, meters and SCADA (OPC-UA, Modbus, BACnet, MQTT) — benchmark across every site.
Automatic stop detection replaces log sheets. Every micro-stop is captured and pinpointed on the line.
Inline vision checks stop the machine on a wrong label or unreadable date code. Every packaging lot is tied to its order.
QA, lab and batch records sit in one auditable system. A hold pulls its own case counts, checks and approvals.
Metering compressors, blow moulder, filler and pasteuriser exposes idle loads, leaks and off-shift waste the utility bill never showed.
OEE multiplies availability, performance and quality. On a filling line, availability is run time against planned production time, performance compares actual output to the filler's rated speed, and quality is good cases against total cases filled. Decide4Action derives all three from the line's own signals, using a single reference counter — usually at the filler or the case packer — so every line is measured the same way.
A micro-stop is a short stoppage, typically under a few minutes, that an operator has no practical way to write down while keeping the line running. A logged downtime event is one someone recorded with a cause. Micro-stops routinely account for a third or more of real losses on high-speed lines, which is why they are detected automatically from machine signals rather than entered by hand.
Every packaging component — cans, bottles, caps, labels, cartons — is scanned as it comes onto the line, so each lot is tied to the production order it ran on. Inline scanning then verifies what actually goes out: labels and date codes are read on the fly, and a fault stops the machine. The result is a complete chain, from incoming lot to shipped case, with each check timestamped against the order — so a trace-back or recall pulls up everything that touched that lot in minutes.
Brix, CO₂, fill height, net content and pH are entered digitally against built-in spec ranges — at the line or in the lab — and flagged the moment they're out of spec. Control charts surface carbonation or fill drift mid-run, and every result is tied to the order and lot, so holds and audits pull complete records instantly.
Yes — any operator form: pre-op, CIP / sanitation, seamer teardown, changeover. Forms carry custom fields, photos and sign-offs, route automatically to the right role for approval, and can trigger what happens next — a notification, a work order, a hold. Every submission is timestamped and traceable.
A layer over the meters and sensors you already have correlates kWh, litres and CO₂ with output — per case, per line, per site — exposing idle loads, leaks and off-shift waste. The same signals feed asset health: vibration, temperature and runtime trends flag equipment drifting toward failure before it stops the line.
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And what that could look like in your operation.
