Terex increase asset
utilisation by 11%
utilisation by 11%
Busroot helps Terex (Dungannon) recognise the critical importance of measuring machine utilisation.
Machinery Manufacturer
Terex Corporation is a global industrial equipment manufacturer of materials processing machinery, waste and recycling solutions, mobile elevating work platforms (MEWPs), and equipment for the electric utility industry
Metal Fabrication
The facility carries out large-scale metal fabrication using advanced processes like robotic welding and precision assembly. It delivers durable, high-quality components at scale, supporting global demand for Terex machinery.
Dungannon, NI
Located in Dungannon, Northern Ireland, the site is part of a major regional hub for manufacturing and innovation. Purpose-built and energy-conscious, the facility reflects Terex’s commitment to sustainability and local investment.
The challenge
Turning gut feelings into real-time insights
Disconnected systems and legacy machinery were holding back data visibility, operational efficiency, and confident decision-making on the shop floor.
Existing legacy machines without connectivity
Varying machine types, brands, and age of the machinery made it difficult to capture accurate data.
Unable to connect existing data to shop floor dashboards
It was not an option or possible to monitor eight siloed software programs from each machine supplier/brand they operate.
Lack of a data-driven decision making
The site team had a gut feeling that utilisation was below target, but they could not back this instinct with reliable real-time data across all machines.
From Visibility to Value: Unlocking Efficiency with Real-Time Data
Terex (Dungannon) installed the Busroot platform on several plasma cutters and press brake machines, immediately providing reliable real-time data on machine utilisation.
This resulted in enhanced downtime capture and enabled the manufacturer to identify areas for process improvement and cost reduction.
Thanks to improved communication between managers and machine operators and interventions informed by analysis of downtime data, Terex (Dungannon) was able to improve the quality of consumables and reduce downtime and waste.
Since the installation of Busroot, Terex (Dungannon) has observed improved machine utilisation levels; initial levels were 82% per cent in Q4 of 2023 and 93% per cent in Q1 of 2024 without the need to increase headcount.
11%
Increase in machine utilisation
£200k
Recovered Productivity value
100%
Data driven decision making
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.
“Using Busroot has helped us gain invaluable insight into our cut shop operations as part of our digital roadmap improvements. We have been able to increase our utilisation, output and efficiency without increasing the headcount. The Output Industries team have provided first class support during start up, and are responsive to making improvements to the software as required.”
Matthew “Bobby” Taylor
Senior Engineering Manager
“The Terex (Dungannon) team's unwavering commitment to innovation and continuous improvement led to excellent insights and significant improvements in such a short period. I’m excited to see Busroot's roadmap come to life across 2024 and the expansion across Terex (Dungannon).”
Michael Wright
CEO & Co-Founder
Ready to boost performance and cut waste?
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