World-class OEE is 85% — only 3% of manufacturers achieve it. Unplanned downtime costs $125,000 per hour. We build predictive maintenance, quality inspection, and production scheduling systems that connect to your existing PLCs, SCADA historians, and sensor infrastructure — using equipment you already have.
3%
Of manufacturers achieve world-class OEE (85%)
$125K/hr
Average cost of unplanned downtime
$1T/yr
Lost globally to preventable machine failure
10–20%
Error rate in manual shop floor data collection
The Problem
29%
Of theoretical output lost at 60% OEE
World-class OEE is 85%. The average discrete manufacturer runs at 55–75%. That gap doesn't show up as a crisis because it's baked into the baseline. But a competitor at 80% OEE produces 33% more output from the same equipment, labor, and floor space. We connect to your existing SCADA historian and PLC data to identify the specific availability, performance, and quality losses driving your OEE gap. Typical first engagement: we instrument your three highest-impact production lines, identify the top failure modes, and deploy monitoring within 6 weeks. Fixed scope, fixed price.
$125K/hr
Median cost of unplanned downtime
The Siemens True Cost of Downtime study across 3,200 plant maintenance leaders found $125,000 per hour as the median cost. Automotive and pharmaceutical sectors exceed $1 million per hour. Yet two-thirds of plants run reactive maintenance. We deploy predictive maintenance models on your existing sensor data — vibration, temperature, pressure, current draw — to catch bearing wear, hydraulic pressure drops, and anomalies weeks before failure. The system connects to your CMMS and triggers work orders automatically during planned downtime windows.
$1–1.5M
Annual carrying cost on $5M in spare parts
Wrong inventory counts trigger wrong procurement orders. Missed defect measurements become customer escapes. Production data informing your scheduling is structurally unreliable. We deploy automated data capture from your existing equipment, sensors, and inspection stations — replacing the manual collection that introduces 10–20% error rates. MRO carrying costs run 20–30% of total parts value; AI-driven optimization reduces inventory costs by 15–30% and emergency breakdowns by 20–40%.
What We Build
We connect to your existing sensor infrastructure — vibration, temperature, pressure, current — and deploy anomaly detection models trained on your equipment's specific failure patterns. The system integrates with your CMMS to schedule proactive maintenance during planned downtime.
Line-speed visual inspection trained on your specific defect types and product geometry. We deploy on your existing camera infrastructure or specify the exact hardware needed — catching defects at the source where correction costs 5–10x less than end-of-line rework.
Machine learning manages HVAC, compressed air, and equipment idle states based on your production schedule. We connect to your BMS and utility metering to deliver 12% average energy savings — on a $500K annual energy bill, that's $60K recovered every year.
AI-driven inventory optimization based on your actual failure patterns, lead times, and criticality ratings. We connect to your CMMS and procurement system to right-size spare parts inventory — cutting 20–30% carrying costs while reducing emergency breakdowns by 20–40%.
Schedules generated from machine capacity, workforce availability, material readiness, and delivery commitments — connected to your ERP and updated dynamically as inputs change. We replace the manual rebuild every shift change with a system that adapts in real time.
Replace 10–20% manual data error rates with automated capture from your existing equipment, sensors, and inspection stations. We integrate with your MES or ERP to ensure scheduling and procurement decisions are built on data you can trust.
Return on Investment
Closing half the OEE gap: significantly more output from the same equipment, labor, and floor space.
The gap between your current OEE and 85% is a multiple of your improvement budget. Add 30% maintenance cost reduction, 12% energy savings, and 15–30% lower MRO carrying costs, and the total impact is a structural shift in plant economics. Every engagement starts with a fixed-scope assessment: we connect to your SCADA historian, identify your highest-cost failure modes and OEE losses, and deliver a system targeting the specific problems in your operation — not generic industry solutions.
Ready to start
A 30-minute discovery call costs nothing. We’ll map your biggest operational bottleneck and tell you exactly what’s automatable.
Book a Discovery Call