Industry Solutions: Manufacturing

Industry 4.0 Intelligence for Smart Factories

Deploy AI at the edge and in the cloud to achieve operational excellence—optimizing factory throughput, automating quality inspection, and predicting equipment failures before they impact production.

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Key Business Outcomes

30%+ reduction in unplanned downtime
99.7% accuracy in automated defect detection
15-25% improvement in OEE metrics
60% reduction in quality inspection labor

Enterprise Solutions

Production-ready AI solutions designed for the specific challenges facing Manufacturing organizations.

01

AI-Powered Visual Quality Inspection

Detect defects invisible to the human eye at full production speed

The Challenge

Manual quality inspection is a bottleneck that costs manufacturers millions. Human inspectors can only maintain peak focus for 20-30 minutes, miss up to 20% of defects, and cannot keep pace with high-speed production lines. A single escaped defect can result in costly recalls, warranty claims, and damaged brand reputation.

Our Solution

Deploy computer vision AI directly on your production line that inspects 100% of units at full line speed. Our models detect surface defects, dimensional variations, and assembly errors with sub-millimeter precision—catching issues that human inspectors routinely miss while maintaining consistent accuracy 24/7.

How It Works

1
High-resolution cameras capture images at each critical inspection point on the line
2
Edge AI processes images in under 100ms for real-time pass/fail decisions
3
Defect classification automatically identifies root cause categories for quality engineering
4
Continuous learning improves accuracy with each new defect type encountered
5
Reject handling triggers automated diversion, line stoppage, or operator alerts based on severity

Business Impact

99.7%
Defect Detection Rate
Near-zero quality escapes reaching customers
100%
Inspection Coverage
Every unit inspected at full line speed
60%
Quality Labor Reduction
Redeploy inspectors to higher-value tasks
$1.8M+
Annual Cost Savings
Reduced scrap, rework, and warranty costs

Key Capabilities

Multi-camera arrays up to 12 viewpointsVariable lighting compensationHigh-speed motion captureMES integration for traceabilityCustom defect model training
02

Predictive Equipment Maintenance

Prevent costly unplanned downtime before it happens

The Challenge

Unplanned equipment failures can cost $5,000 to $50,000 per hour in lost production. Traditional time-based maintenance leads to either premature part replacement (wasted resources) or unexpected breakdowns (production losses). Maintenance teams lack visibility into actual equipment health and are reactive rather than proactive.

Our Solution

Deploy industrial IoT sensors across critical equipment to continuously monitor vibration, temperature, acoustic, and electrical signatures. Our AI models detect subtle anomalies weeks before failure, predict remaining useful life, and recommend optimal maintenance windows that minimize production impact.

How It Works

1
Wireless sensors collect high-frequency data from motors, bearings, pumps, and drives
2
AI models trained on your equipment's normal operating patterns detect deviations
3
Failure mode classification identifies the specific component likely to fail
4
Remaining useful life predictions enable optimal maintenance scheduling
5
Automatic work order generation integrates with CMMS for seamless workflow

Business Impact

-30%
Unplanned Downtime
Fewer surprise failures disrupting production
-25%
Maintenance Costs
Right-time maintenance replaces calendar-based
+20%
Equipment Lifespan
Early intervention prevents cascading damage
94%
Prediction Accuracy
Reliable forecasts for maintenance planning

Key Capabilities

Multi-sensor fusion (vibration, thermal, acoustic)Anomaly detection without failure historyRemaining useful life predictionCMMS integration (SAP PM, Maximo, Fiix)Mobile alerts for maintenance teams
03

Dynamic Production Scheduling

Optimize shop floor operations in real-time as conditions change

The Challenge

Static production schedules cannot adapt to the reality of the shop floor—machine breakdowns, material shortages, rush orders, and quality holds create constant disruptions. Schedulers spend hours manually adjusting plans, and suboptimal sequencing leads to excessive changeovers, bottlenecks, and missed delivery commitments.

Our Solution

Implement AI-driven production scheduling that continuously optimizes job sequencing based on real-time constraints. Our system balances throughput, due dates, changeover costs, and resource availability—automatically re-optimizing whenever conditions change and providing schedulers with decision support for complex trade-offs.

How It Works

1
Real-time data ingestion from MES, ERP, and shop floor systems
2
Constraint modeling captures machine capabilities, tooling, labor, and materials
3
Multi-objective optimization balances throughput, on-time delivery, and efficiency
4
What-if simulation enables planners to evaluate scenarios before committing
5
Automatic schedule updates when disruptions occur with change impact visualization

Business Impact

+15%
OEE Improvement
Reduced changeovers and optimized sequencing
97%
On-Time Delivery
Realistic schedules that account for constraints
-20%
Changeover Time
Intelligent job grouping minimizes setups
3x
Planner Productivity
Focus on exceptions, not manual scheduling

Key Capabilities

Real-time constraint optimizationFinite capacity schedulingWhat-if scenario simulationERP/MES bidirectional syncDrag-and-drop schedule adjustment

Enterprise Integration

Seamlessly connect with your existing infrastructure. No rip-and-replace required.

Factory Floor Systems

Connect directly to your PLCs, SCADA systems, and manufacturing execution systems without custom middleware or disruptive integrations.

OPC-UA Protocol
Real-time bidirectional communication with Siemens, Rockwell, Mitsubishi, and all major PLC vendors
MQTT Messaging
Lightweight IoT data streaming for sensor networks with guaranteed delivery and edge processing
MTConnect Standard
Plug-and-play connectivity for CNC machines and production equipment with standardized data models

Enterprise Systems

Seamless data flow between shop floor intelligence and business systems for unified visibility across your operation.

SAP S/4HANA Manufacturing
Push quality data to QM module, sync production orders, and automate goods movements
Oracle Manufacturing Cloud
Bidirectional integration for work orders, inventory, and quality management
Siemens Opcenter
Native MES integration for detailed scheduling and production execution tracking

Standards & Compliance

Built for regulated manufacturing environments with audit-ready architecture and industry-standard compliance.

ISA-95 / IEC 62264
Clean integration boundaries between enterprise and shop floor layers following industry standards
FDA 21 CFR Part 11
Electronic records and digital signatures for pharma and medical device manufacturing
IATF 16949
Automotive quality management system alignment for Tier 1-3 suppliers

Ready to Transform Your Manufacturing Operations?

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