Live performance monitoring boosts manual production by 6%
Discover how this gift assembly operation used Busroot to eliminate manual tracking, empower operators, and boost performance with real-time, actionable shop floor data.
Gift Assembly Operation
A UK-based gift assembly team producing high volumes of packaged SKUs, requiring close coordination and accurate performance tracking.
High-Volume, Varied Output
Products with complex cycle times and changing team sizes, each operation measured by seconds and requiring a dependable way to monitor progress and targets.
Multi-Team Production
Multiple teams work simultaneously, with performance management and output tracking central to meeting customer deadlines and targets.
The challenge
Manual performance checks caused friction and missed targets.
Tracking output relied on staff physically counting assembled gifts, cross-referencing hours worked and output – a process prone to delays and errors.
1. Resource-intensive reporting
Performance checks took place 2-3 times a day, with first counts happening hours into the shift – risking unrecoverable issues to meet daily targets.
2. Team leader friction over results
Sharing underperformance data created unnecessary confrontation. Teams preferred seeing their own results and becoming responsible for improvement.
3. Missing actionable metrics
Management needed clear reporting, visual breakdowns of lost time, and more intuitive ways to understand asset utilisation and causes of underperformance.
Busroot delivers instant feedback, shared accountability, and measurable performance gains
Liz Earle adopted Busroot for off-the-shelf, unobtrusive tracking - instead of costly, bespoke systems and eliminating manual counting. With Busroot, operators now see real-time performance charts on shop-floor screens; leaders and managers have “always-on” visibility from anywhere.
Key benefits include:
- Teams now manage and react to their own performance, reducing friction and relying less on managers for progress updates.
- Management can identify lagging production and intervene fast, preventing missed targets.
- The platform’s flexibility ensures every second counts and targets are maintained on dynamic, minute-by-minute cycles.
6%
Average performance improvement across ten core all‑year‑round SKUs after implementing Busroot, measured in units packed per minute per SKU.
233 hours
Packing time saved in the first 12 months.
£6.5k
Real-time visibility has replaced manager/team leader confrontation with operator ownership and self-correction. The approximate annual labour benefit combining 233 hours of saved packing time and 1 hour a day in team leader time savings.
Automatic downtime detection
Busroot picks up changes in machine state and logs downtime instantly
Operator input & reason codes
Operators can quickly assign a reason - so you get context, not just a timestamp
Downtime categorisation
Group stops by type (e.g mechanical, material, planned) for clearer analysis.
Root cause analysis
Drill into trends to understand what's driving the most frequent or costly stops.
Visual timelines
See when downtime happened across the shift and spot recurring patterns
Real-time alerts
Get notified when a machine goes down - action can be taken immediately.
“Busroot transformed our operation. Instead of having managers walk the floor counting output, our teams see their own performance instantly and take ownership. We saw a 6% increase in performance in our first year, with zero increase in headcount.. The chart is always open on my screen. The primary goal was to remove friction in giving performance feedback and empower teams with transparent, real-time data - which the team considers fully achieved. I’d recommend it for any production team.”
Tim Shaw
Operations Supervisor
“Tim’s team’s rapid adoption shows what happens when you replace manual logging with transparent, actionable data. Their performance speaks for itself, and we’re excited to support new automation features soon.”
Michael Wright
CEO & Co-Founder
Ready to boost performance and cut waste?
Book your demo and see how Busroot unlocks visibility, accountability, and real-time action - without disrupting your operation.