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Uptime, yield and energy, measured
Industry 4.0 systems that connect the plant floor to the balance sheet — OEE visibility, quality automation and predictive maintenance.
Our position
Most manufacturers have more data than they can use and less visibility than they need. The PLCs know what happened; the finance system knows what it cost; nothing joins the two in time to act. We build the layer that does, then use it for the things that pay: uptime, first-pass yield and energy.
Challenges
These are the problems that come up in a first meeting, with the cost of leaving each one unaddressed.
Availability, performance and quality tracked on whiteboards and reconciled monthly, if at all.
Visual inspection that is slow, inconsistent between operators and impossible to audit.
Fixed-interval servicing that either wastes component life or misses developing failures.
Production reality and system-of-record diverge, so planning works from stale numbers.
Load profiles unmanaged against tariff structures and load-shedding schedules.
What we build
Live availability, performance and quality per line, with automatic downtime reason capture.
Automated defect detection at line speed, with every judgement image-logged for audit.
Condition monitoring across motors, pumps and bearings, prioritised by production criticality.
A reconciled flow from work order to shop floor to finished goods to invoice.
Load profiling against tariff windows, with scheduling recommendations and load-shedding readiness.
Version-controlled instructions at the station, with sign-off and traceability.
AI opportunities
Ranked by how proven the approach is. We are explicit about what is experimental, because deploying an experiment as though it were proven is how AI programmes lose credibility.
Vision models catching defects at line speed that human inspection misses under fatigue.
Models recommending setpoints that maximise yield against current input variability.
Improved forecasts driving inventory and production planning.
Machine condition inferred from sound, requiring only a microphone rather than new sensors.
How we deliver
Questions
The questions we are asked most often by operators in this sector.
Tell us what you are trying to change. We will tell you honestly whether we can help and what it would take.