A plant virtualized and kept in sync with its MES
Real-time telemetry, a twin synchronized with the MES context, 3D simulation, live metrics and recommendations on the process.
Newboot Process Ops®
See your process live and fix it before it drifts.
Newboot Process Ops models your lines and equipment as a digital twin synchronized in real time, so teams track performance, spot losses and test changes before they touch production.
6–12% energy saved at Le Pontet
−20% downtime*
+15% operational efficiency*
Digital twin · Line 2
Live
OEE78.4%+2.1 pts
Throughput1,240parts/h
Cycle time2.9 starget 2.8 s
Bottleneck detected
Forming station: 3 micro-stops in 20 min, −6% throughput
Scenario: +4% speed on the furnace outlet → simulated before rollout
Illustrative view
The problem
Performance is explained after the shift, not during it.
Energy and cycle times drift
From one shift and one site to another, with no single view to compare them.
Stoppages are explained too late
Micro-stops and bottlenecks show up in reports, once the losses are already made.
Every dashboard is an IT project
Each new indicator means new integrations, new scripts and new delays.
Key features
A platform to build your operational apps on a live model of the plant.
01
Process and equipment modeling
Lines, machines, flows and recipes described once, with the business meaning of each variable.
02
Digital twin synchronized in real time
Fed by live PLC and MES data through Newboot Edge, with history for every value.
03
KPIs computed for you
OEE, throughput and cycle times, by line, shift and site.
04
Stoppages, drifts and bottlenecks
Detected as they happen and attributed to the right station.
05
Scenarios simulated first
Test a speed, a recipe or a schedule on the twin before it reaches the line.
06
APIs, HMIs and 3D
Build your own business apps, and view the plant in 3D with NVIDIA Omniverse.
Customer story · Saint-Gobain, Le Pontet (France)
A digital twin that cuts the energy of glass furnace heat-up.
Heating a glass furnace is one of the most energy-intensive steps of the process. The goal: find the optimal heat-up cycle for each composition, and give it to operators in real time.
How it works
- Newboot Edge streams PLC data and the furnace context to the cloud.
- AI models compute the optimal heat-up from composition, temperature and other parameters.
- The recommendation is sent back to the operators, on the line.
Consumables optimized from live consumption
Consumption and manufacturing context sent to the cloud, where models forecast stock from daily use.
* −20% downtime and +15% operational efficiency: indicative figures observed across Newboot deployments.
FAQ
Questions from operations teams.
Do we need to replace our MES or SCADA?
No. Process Ops reads data from your existing PLCs, MES and SCADA through Newboot Edge and builds the twin on top of them.
Which data feeds the digital twin?
Live PLC and sensor data, MES context (orders, recipes, operators) and the history of each value.
Which indicators are available out of the box?
OEE, throughput, cycle times, stoppages and their causes, by line, shift and site. Energy indicators are added where meters are connected.
Can we build our own applications?
Yes. APIs and HMIs let your teams build business apps on the same model, and AI agents can query it through the Newboot MCP server.
Next step
Pick one line and one loss to fix.
Energy, stoppages or cycle times: we start from the indicator that matters most to you.
- 1Scoping workshopIdentify the priority use case and the data available.
- 2PilotProve the value on one line, one site or one IT scope.
- 3Deploy and replicateIndustrialize, then roll out to other lines and sites on the same foundation.