What we deliver, anchored to KPIs.
Every engagement names the metric, agrees on the baseline, and verifies the lift. We start with the fundamentals of your process, then use the right technology and methodology to move the needle in the right direction.
Let us know how we can help →Five places where AI delivers the most value.
Most plant-floor value clusters into five themes. We start where your highest-value, most-ready opportunity lives.
Throughput & OEE
The line runs, but rarely at nameplate. Micro-stops nobody logs, slow cycles, and changeovers that run long. Ask five people where the bottleneck is and you get five answers.
A shared, honest view of where the hours actually go. Losses tied to a real cause instead of a hunch, and a constraint you can prove instead of argue about.
Break OEE down into its real losses across availability, performance, and quality, find the true constraint, and put the next best action in front of the crew running the line. Fix it, then move to the next one.
Equipment Reliability
Six-figure-per-hour downtime. Calendar-based maintenance. Chronic bad actors everyone knows by name, and a firefighting culture that never gets ahead of them.
An integrated view of process and maintenance data, repeatable failure signatures, and an owner after the pilot ends.
Combine predictive maintenance with failure-mode effects analysis, optimize preventative maintenance plans, and use unsupervised machine learning to catch outliers and anomalies before your equipment fails again.
Quality
Every crew runs the unit a little differently, so results drift shift to shift. Lab feedback comes back late and can't always be trusted, and by the time you see the problem, the product is already made.
A clear read on which process signals actually move your quality numbers, and guidance operators believe enough to act on.
Use multivariate quality analytics (MVA) to connect the process signals that matter to the quality outcomes you care about, so the people running the plant can steer before it goes out of spec.
Yield & Raw Material Utilization
More raw material goes in than the recipe calls for. It shows up as giveaway, off-spec blends, and rework nobody fully accounts for. Theoretical yield and actual yield have a gap, and nobody owns it.
A tight link between operating conditions and where material is lost, and a way to see conversion loss while there's still time to correct it.
Model what actually drives yield, expose where material is lost, and put live targets in front of operators to close the gap between theoretical and actual, batch after batch.
Energy & Sustainability
Energy is your largest variable cost. Heat-exchanger fouling, steam leaks, and controls left in manual quietly eat it, undetected for months.
Meter-level attribution, asset-level optimization targets, and the sustained focus that keeps them honest.
Energy baselining, optimization ranges delivered in the control room, and continuous improvement as a managed service.
The full toolkit. Methodology first, technology second.
We don't lead with the algorithm. We start with your problem, then bring the right capability to it. Technology is an enabler, not the destination.
Digital Transformation Roadmap
A sequenced, fundable plan that moves you out of pilot purgatory and into scaled value, supported by the data architecture and governance needed to sustain it.
Generative AI
Practical GenAI that runs on your own contextualized data. Ask natural-language questions to solve your most complicated process and chemistry questions. Context is king here, and without the context, the large language model is just guessing.
Machine Learning
Transparent models you can explain and defend: PCA, PLS, gradient boosting, and others. We use them for prediction, soft sensors, outlier and anomaly detection, and changes in operating conditions. We build them to run on shift.
Predictive Analytics
We turn your historical and real-time signals into early warnings on yield, quality, energy, and reliability. The point is to catch the problem before the loss shows up in the numbers.
Outlier & Anomaly Detection
We surface the abnormal conditions that matter most, such as plugged valves, drifting control loops, and the bad actors that erode your uptime, and route them to the people who can act on them.
LEAN Six Sigma & DMAIC
We're not here to replace a proven methodology. We're here to run it faster. AI moves you through Define, Measure, Analyze, Improve, and Control with the discipline intact. The methodology came first. AI accelerates it.
Process Optimization
Stabilize the process first, then lift throughput, yield, quality, and energy. Under the hood it's bottleneck analysis, setpoint strategy, and bad-actor elimination. At the end of the day we're only ever doing two things: reducing variation or moving the average.
Statistical Process Control (SPC)
The most underrated tool in the toolkit, and we deploy it at scale. SPC gives every operator a consistent, teachable view of process health that reads the same on every line and every site. Simple enough to run on shift, strong enough to deliver value at scale.
Change Management
The hardest part, and the part most people skip. Standing up the tool takes months. Getting people to actually use it, shift after shift, takes years. We do the unglamorous work: sponsor mapping, leader standard work, and the adoption habits that make a new way of working stick.
Actionboards
We banned the word “dashboard.” A dashboard shows you data. An Actionboard tells you what to do with it. Every item on the Actionboard answers three questions: what is the action, who owns it, and are they trained and equipped to take it? If an item cannot answer those questions, it does not belong on the Actionboard.
Signature Methods
Field-tested frameworks, proven at enterprise scale.
The AI Highway
PPDTG Maturity Model
AI Accelerated LEAN Six Sigma
Actionboards, Not Dashboards
Operationalizing AI
Daily Rapid Problem Solving
See It. Solve It. Scale It.
The same governed data underneath. What changes is the altitude, and the decision it has to support.
At the Console
Ground level: this line, this shift, this hour. The system answers small questions fast, because small questions are what keep a plant on spec.
At the Workbench
Mid-altitude: patterns across batches, lines, and weeks. Enough context to explain variation, enough rigor to defend the finding.
At the Altitude of the P&L
Top of the stack: sites, programs, and quarters. Value roll-ups tie the console and the workbench to the number the business runs on.
DMAIC, at the Speed of Your Data.
The same discipline your belts already trust, with AI compressing every phase from quarters to weeks, and none of the rigor lost on the way.
Name the problem, the KPI, and the baseline.
Scope the problem where the value is: a charter with a named KPI, an agreed baseline, and the sites in scope, signed before any analysis starts.
AI acceleration: AI mines work orders, deviation logs, and downtime codes to surface and size the biggest recurring problems, so you charter the right project, not the loudest one.
Trust the data before you trust the analysis.
Automated pulls from historian, MES, and LIMS with data-quality checks and measurement-system sanity built in. Baseline capability computed, not guessed.
AI acceleration: Contextualization and automated data prep replace months of manual collection. The dataset arrives analysis-ready.
Find the vital few, prove them causally.
SPC and capability first; multivariate screening across thousands of tags ranks the suspects. Engineers confirm root cause with evidence, not opinion.
AI acceleration: ML feature-ranking shortlists suspect variables in hours, so your engineers spend their time verifying, not hunting.
Pilot the fix, verify the delta.
Design the countermeasure, trial it under control, and verify movement against the agreed baseline before declaring victory.
AI acceleration: What-if simulation and optimization test candidate settings before you touch the line: fewer trials, faster convergence.
Make it stick, automatically.
Control plans become live monitoring: SPC limits published to the Actionboard, drift watched around the clock, recurrence flagged to an owner.
AI acceleration: The model keeps watching after the belt moves on. Control becomes a system, not a binder.
Small Problems, Solved Daily, Compound.
Actionboards surface today's issues. Every locked-in fix adds to a return that never resets.
"A Dashboard shows data, but an Actionboard drives behavior."