Case Studies
Real Results from Applied AI
See how manufacturers are using AI to solve real problems.
Live Production Dashboards Connected to PLCs
Company: Precision Parts Manufacturer
Problem: Production reports compiled manually at end of shift—by the time problems were visible, the damage was done and scrap rates hit 12%
Solution: Real-time dashboards pulling directly from machine PLCs—live OEE, throughput, and quality metrics visible on factory floor, cut scrap to 4% by catching issues immediately
Automated Downtime Tracking
Company: Injection Molding Operation
Problem: Operators manually logging downtime on paper—data entry took 2 hours daily and downtime causes were often wrong or missing
Solution: System automatically captures machine stops from PLCs and prompts operators via tablet to categorize cause—downtime data now 100% accurate with zero manual entry
Predictive Maintenance System
Company: Food Processing Plant
Problem: Unplanned equipment failures caused 20+ hours of downtime monthly—reactive maintenance was killing throughput and increasing costs
Solution: AI models analyze sensor data from critical equipment to predict failures 2-3 weeks in advance—maintenance scheduled during planned downtime, unplanned stops reduced 85%
Quality Control Vision System
Company: Automotive Parts Supplier
Problem: Manual visual inspection caught only 80% of defects—customers rejecting shipments and threatening to pull contracts
Solution: AI-powered vision system inspects 100% of parts at line speed—defect detection rate above 99%, eliminated customer rejections and saved the account