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The plant produces more signal than anyone has time to read: sensor history, shift logs, defect records, inspection photos, and the forms that move between the line and the office.
I build workflows over that material — a machine drifting toward failure raised before it stops the line, an out-of-spec part caught during the run, a cause pulled out of logs nobody has time to cross-reference.
It has to work with the MES, historian and quality system you already run. Nothing gets ripped out, and an uncertain call goes to a person rather than being made quietly.
Anomaly detection over sensor history, so a machine drifting toward failure raises a work order before it takes the line down.
Vision and process-control models that catch an out-of-spec part at the line rather than at final inspection.
Dashboards fed from what the machines already report, showing where the line loses time rather than where people assume it does.
Buffer levels worked out from demand and the lead times your suppliers actually hit, so material is on hand without paying to store months of it.
A schedule proposed from machine constraints, changeover times and who is actually on shift, for a planner to adjust rather than build.
Anomaly detection across sensor history
Vision inspection on the line
Search across shift, defect and batch logs
Works with the MES you already run
Maintenance is reactive. The team answers failures rather than preventing them, and an unplanned stop takes out the rest of the shift.
Sensor telemetry is ingested and scored for anomalies, so a machine drifting away from its normal pattern raises a work order before it reaches the failure threshold.
Defects are found late in the process, by which point the rework cost is already sunk and some of the batch has moved on.
In-line detection from process sensor data and statistical control charts, flagging drift while the run can still be corrected.
Production gaps can only be picked apart after the fact, so the conversation about a bad week happens a week late.
Dashboards fed from machine data, with shift-level comparison and an alert when the bottleneck moves to a different station.
I walk the floor and the data: which sensors already report, what the shift and defect logs actually contain, and where a stoppage or a scrap batch costs you the most.
I design against the SCADA, MES and ERP you already run, so what gets built is an addition to that stack rather than a replacement for part of it.
It runs on one line beside the current process and gets checked against failures and defects you already know the answer to, before anything depends on it.
It extends across lines and sites, and I keep monitoring and retraining it as equipment, tooling and conditions change.
Tell me where the floor loses the most time or the most material, and I will tell you whether it is worth building for.
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