Production Genie connects planning, production monitoring, process, flow, quality, counting and dispatch into one system — configured to your company, your plants, your lines, your shifts and your operators. Run it on the cloud, on your own servers, or fully integrated with KVAR sensors, loggers and displays.
A standalone production monitor is a complete answer for one line — live count, OEE and downtime on the machine. Production Genie is the step up: the same production intelligence, plus planning, process, flow, quality, counting and dispatch, joined together and rolled up across every plant you run.
Take one module, take them all, or keep scaling — add modules, lines and plants on the same platform, with the same login, whenever you are ready. Every module comes with the counters, sensors, displays and alarms it needs, in Basic, Advanced and Premium editions.
Because they run on one platform, the plan knows the machine’s real capacity, quality knows the shift, and the count feeds them both — without anyone re-keying anything.
Plans the order book against real capacity — each order costed in stage times, scheduled against the hours the teams actually have, and released to the floor as clockable work. A promise date is calculated, not guessed.
Live output against target, OEE, and downtime with reasons — per line, per shift and per operator. The integrated version of the standalone monitor, rolled up across the plant.
Inspection and rejection captured as it happens, against a checklist, with root-cause and recurring-defect analysis — quality reported per line and per shift, not as one monthly number.
Bags counted on the conveyor by hybrid sensing, verified against the dispatch lot and cross-checked on weight; the bay barrier releases only on a complete lot, printing a dispatch slip from measured data. Truck Terminal is also available as a dedicated solution in the catalogue (animation, hardware & options).
Accurate piece and batch counting on any line — parts, packs or bags — with pro-rated targets, reject counts and a large display the whole floor can read. The count everything else builds on.
Critical process parameters logged continuously with high/low bands, so a deviation raises an alert while it can still be corrected, and the batch record writes itself.
Flow totalising for batching, dosing and utilities — consumption logged per line, per batch and per shift, with alerts on abnormal flow.
Production Genie is set up as a model of your business, top to bottom. Everything below is configuration in the software, changed as your operation changes — no re-development.
Plants, lines, shifts, operators, targets, thresholds and reason codes are all set in the software.
Operator, supervisor, plant head and management roles — each sees and does only what its role allows.
Compare plant against plant, line against line and shift against shift from one management view.
Orders in, actuals out — REST API or scheduled Excel/CSV to SAP, Tally, Oracle or any ERP / MES.
The same platform, delivered to suit your IT policy and how much of the stack you want from KVAR.
For distributed and multi-site operations that want one view without running servers.
For data-sensitive plants and IT policies that require on-site hosting.
For greenfield lines and full-stack rollouts that want hardware and software from one team.
| Cloud | On-premise | Integrated | |
|---|---|---|---|
| Where it runs | KVAR secure cloud | Your server / network | Your choice, cloud or on-prem |
| Data location | Cloud | On your site | Cloud or on-site |
| Hardware | Use your existing instruments | Use your existing instruments | KVAR sensors, loggers & displays included |
| Access | Any browser, anywhere | On the network (VPN optional) | Both |
| Multi-site roll-up | ✓ | Per server | ✓ |
| Updates & backup | Managed by KVAR | Managed by you | Managed by KVAR |
| Time to go live | Fastest | Moderate | Fast, full stack |
| Best for | Distributed / multi-site | Data-sensitive plants | Greenfield / full stack |
Editions are software feature-gates, so you start where you are and move up without changing anything on the floor.
| Capability | Basic | Advanced | Premium |
|---|---|---|---|
| Live monitoring & dashboards | ✓ | ✓ | ✓ |
| Shift & operator data | ✓ | ✓ | ✓ |
| OEE, downtime & reasons | ✓ | ✓ | ✓ |
| Automatic reports (Excel / PDF) | — | ✓ | ✓ |
| Planning module | — | OPT | ✓ |
| Quality & Counting modules | — | OPT | ✓ |
| Process & Flow modules | — | OPT | ✓ |
| Truck Terminal module | — | OPT | OPT |
| Role-based access & escalation | Single | Role-based | Role-based + escalation |
| Multi-plant / multi-line roll-up | — | OPT | ✓ |
| Pareto, trend & comparison analytics | — | ✓ | ✓ |
| ERP / MES integration (API) | — | OPT | ✓ |
| Mobile & management dashboards | — | ✓ | ✓ |
✓ included OPT optional module / add-on — not in this edition. Every solution comes with counters, sensors, displays of various sizes and alarms, with configurable thresholds. Editions and modules are scalable and configurable — on cloud or on-premise, from one factory to many. Priced by the modules selected, the number of plants, lines and users, the edition and the deployment.
One platform replaces the spreadsheets, the whiteboards and the end-of-month reconciliations — and pays back in recovered hours and decisions made on data.
Recover lost hours — see and fix the downtime you are paying for today, across every line.
Promise dates you can keep — planning against real capacity, not a wish.
End the disputes — dispatch, quality and shift numbers measured, not argued.
Maintain on real hours — service by running time, cut breakdowns before they stop the line.
One version of the truth — every plant, line and shift on one platform, one login.
One supplier — hardware and software from one team, live in days, one number to call.
Production Genie is KVAR Technologies’ integrated production platform. Modules, editions and deployment are configured to the operation; a firm quotation is prepared against your requirement. Contact KVAR Technologies for a demonstration and a configuration matched to your plants.