XL810: what's new

XL810 - real-time data for production and performance management

What's New With XL?

The XL800/810 is amazing value for money as there are no expensive ongoing software licence fees or lease payments.  As a result payback periods are unrivalled.

It is also a living, breathing, and continuously improving product that does have updates that are available.

The newest software (version 2 and higher) runs on an entirely new platform. Here are the latest release features:

XL810 Version 2.12 (September 2020)

Heat Map Charts

Compare with color. Instantly spot problems.

Using color to visualize metrics is extremely effective for quickly spotting areas of concern – or areas where you are doing exceptionally well.

Choose from four different types of heat map charts: time (e.g., OEE over Time), dimension (e.g., OEE by Part), dimension over time (e.g., Utilization by Plant over Time), or dimension by dimension (e.g., Labor Efficiency by Asset by Team).

Powerful New Chronograms

We’ve packed them full of useful new features.

We have completely redesigned the chronogram – with a huge array of new features:

  • Stack multiple chronogram strips with different data dimensions to clusters to visually discover patterns in your data.

  • Use the new palette control to apply heat map colors.

  • Use the new text overlay control to show dimension values and up to three metrics per event.

  • and more

New Live Controls

The fastest path to dashboard perfection.

The KPI and Chronogram elements now feature “live” controls, providing easy configuration to customise your dashboard

Improvements for Changeovers

New reports. New options.  We’ve updated the Changeover deep dive page to include:

  • New pareto chart of changeover reasons.

  • New hierarchical table of changeover reasons with drilldown into individual events.

XL also now includes an option to start changeovers via digital inputs to ease integration with other systems.

Manual Run Detection

Handy for applications with long cycle times. Eg Cutting, blending, mixing processes

For processes with long cycle times, it can often be better to control run detection from an external source running/not running signal, vs the normal count signal. Now XL provides three ways to externally control the run detector using:

  • Digital input (typically from a PLC)

  • Barcode scan (typically by an operator)

  • XL API (typically through integration with other applications and systems)

Detecting State After No Production

A subtle but useful improvement for operators.

When a break or changeover ends, there is often a short period of time before running production can be detected. XL now assigns a temporary production state to this time and displays “Detecting… Run or Down” on the scoreboard to let the operator know that XL is automatically detecting the state. As soon as XL detects that the process is running or down, the scoreboard updates with the new production state and XL automatically adjusts the underlying event.

Improvements for Reject Reasons

New reports. New dashboard functionality.

We’ve made reject reasons a full-fledged analytics dimension. This means they are available throughout the reporting interface, including custom dashboard tables and charts.

We’ve also added new out-of-the-box charts to the Quality Loss deep dive page, including the ability to analyze rejects by production phase, production state, and shift.

Additional Features

As always…lots of “smaller” improvements as well.

  • Discontinuous Events: If a changeover, down, or maintenance event (i.e., production) is split by a meal/break or meeting (i.e., no production) the two parts are now automatically treated as a single event.

  • Reject Reason API Support: You can now submit reject reasons with count quantities through the XL API to enable easy integration with other systems and applications.

  • Part Barcode Duplicate Scans: Scanning the barcode for a running part will now start a new part run for the same part. This enables running the same part twice in a row. It also enables changing part settings and having the new settings immediately take effect.

  • Scoreboard Format Options: You can now set the number of decimal places for cycle times (as well as percentages) displayed on the scoreboard, which is particularly useful for long cycle time applications.

  • Display Time of Day: There is now an option to display time of day on the scoreboard.

See more detail and images in the News section

XL810 Version 2.11 (March 2020)

Automated Shift Reports 

Your team can now receive an instant end-of-shift summary report from XL Enterprise with key metrics, comprehensive loss information, and a summary of all part runs for that shift. 

Enterprise-Aware Dashboards

With the addition of the KPI and KPI Group, all five dashboard elements are now enterprise-aware, which means they can show rolled-up data for any level of your enterprise hierarchy. For example, you can use a KPI element to show the OEE for a single asset, for an entire area, or for your entire plant.

Multiple Dimension Charts

Dimensions are descriptive values that refer to a qualitative attribute of production, such as the Shift, Asset, or Hour. XL includes twenty different analytical dimensions and now you can create charts that incorporate multiple dimensions. Eg: Down Time by Reason by Shift, OEE by Team by Hour.

Text Message Alerts

If your mobile carrier supports email to text message gateways, you can now choose to receive alerts (real-time notifications based on metrics, production state and targets) as text messages instead of emails. (charges may apply)  

More Ways to Scan Parts and Jobs

Scan your existing work orders and product barcodes to start part runs or jobs, or with a mouse click, or via the XL API..

Import Jobs from Excel

You can now export jobs from XL as a Microsoft Excel spreadsheet, make any desired updates, and then import the updated jobs back into XL. It is easier than ever to quickly and efficiently configure jobs.  

XL also supports direct integration with other systems and applications using the XL API. You can use this API to push information to XL (e.g., job parameters) or to retrieve information from XL (e.g., job metrics)


The XL API now supports triggering inputs. Eg forcing a down event

XL810 Version 2.10 (January 2020)

Automated Email Alerts. 

Automatically send email alerts to key employees based on how your process is running. Alerts are delivered by XL Enterprise, which is a cloud-based SaaS application developed by Vorne as an integrated part of the XL platform.

Labour Efficiency Tracking

XL now calculates earned labour time and labour efficiency based on target labour times you define for each part. Instantly know if you are meeting or beating your labour standards.

Faster Reject Entry

Now XL makes this even easier with a new feature that enables operators to scan multiple rejects at once. Simply scan the a barcode for the qty of rejects followed by the reject reason to include them in the current shift and part run.

Improved Run Detection

Choose between cycle or speed based down detection.

Split Down Events

Scan the new Split Down Event barcode to separate one stop into a sequence of down events, each with its own reason.

End Events by Target or Running

XL now directly supports a new option for ending events, “By Target Time or Definitely Running”. Your event will automatically end by whichever occurs first.

XL810 Version 2.9 (June 2019)

Track and analyse Teams and Labour metrics. 

​Analyse any of existing 100+ metrics by new team or labour dimensions. Use a new deep dive page for built in reports, or use them in your own custom dashboard pages ​

Simplified cycle metrics

​For easier understanding cycle metrics now focus on running and small stops. A new Equipment cycle is added to assist with cycle based asset care programs

Improved Top Losses

Now includes a KPI bar to give a quick summary OEE and it A, P, Q components

Filtering on Analyse Pages

New filtering ability on the Analyse deep dive pages. Filter data by Shift, Part, Team,Production Phase, Shift Hour.

Mobile Friendly Navigation.

Redesigned to work seamlessly with large and small device screens


XL810 Version 2.8

Andon Dashboard Page.

​See a real-time, highly visual picture of the current state of manufacturing.


Stacked Chronograms

Stack and compare multiple assets TPT across a synchronized timeline.


Native Excel Export

Easily export data directly to an Excel file. Export tabular data from any page or view, or create your own export formats using dashboard tables with any combination of metrics and dimensions.


Micro MES

Ability to configure jobs directly in XL and start them with a click of a mouse. Start jobs with barcodes, or by clicking a mouse.


Import and Export Parts

Easily add new parts and update existing parts.  ​Import or export all part settings, such as Ideal Cycle Time, Takt Time, Down threshold, and Start with Changeover for up to 1,000 parts.

XL810 Version 2.7 and Earlier

Help Videos  

Short and focused videos make it super-fast and super-easy to learn XL


Loss Report Tooltips. 

Tool-tip includes a time analysis, count summary, OEE metrics, and Six Big Loss details

XL Enterprise

XL Enterprise is our cloud-based platform, and in this first release it delivers free software updates to your XL devices. You maintain full control. Decide if you want XL to check for updates automatically. XL loads updates in the background and you simply click to install. 


Shift Hours.  

Hour-by-hour boards are particularly popular in automotive and in lean manufacturing. We’ve brought the concept to XL by aligning hour-based reporting to your shift schedules.

Clear Selected History

One piece of incorrect information can erode trust in your data – so keep it pristine. If despite your best efforts, accurate data collection is compromised for a short period of time – clear out just the inaccurate information and make decisions based purely on pristine data.

Automatic changeovers made even simpler.

One screen for tracking changeovers. Associate a specific changeover reason with each part, a target time, and how the changeover should end.

Use Your Own Part Barcodes

Scan existing actual product barcodes to start production


Automatic Conversion of Down Events

When XL detects a short down event immediately before a changeover it now runs a quick analysis based counts, cycles, and down reasons, and where appropriate converts the down event to be part of the changeover.


Save and Share Pages

Create, save, and share Dashboard, Advanced Analytics, All Production, and Historical All Production pages with all of their settings so you can instantly come back to your preferred views.

Automatically Detect Startup Rejects

XL automatically categorises rejects that occur during changeovers and initial production as startup rejects (as differentiated from production rejects). You can configure the amount of time that is considered “startup” to best match your manufacturing process.

Metric Alerts

XL now alerts you when key metrics are out of their desired range. You can configure over 20 metrics (e.g., OEE, Efficiency, Down Loss, Cycle Loss, and Quality Loss), each with four ranges: Normal, Caution, Warning, and Critical. Metrics automatically change colour on the scoreboard and web interface based on alert status, and alert notifications are additionally delivered through the web interface.


Reject Reasons

XL now provides comprehensive quality analytics, with a reject reason logged with every rejected part. Reject reasons can be logged through digital inputs or barcode scans. An unlimited number of reject reasons can be configured and the resulting data can be charted, trended, and more.


Run Screen Configuration

Now you can configure your own run screen – in just seconds. An instant preview shows you exactly what the run screen will look like, including easy-to-change text labels. Each metric can be displayed in real-time for the current shift, part run, or hour.

Hidden Factory Metric

XL now includes a Hidden Factory Time metric, which measures the gap between fully productive time and all time. This gap includes all losses (including capacity losses), and represents how much production time would be reclaimed if you were running around the clock, making only good parts, as fast as possible, with no down time.



Organise information in whatever way works best for you. Create an unlimited number of dashboards from Chart, Chronogram, KPI, KPI Group and Table widgets. Create local dashboards for personal use or share dashboards with your entire team.

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