Lean Process Intelligence System
$93K annual savings
Applied manufacturing KPIs to AI agent workflows — real-time waste detection, quality gate automation, supplier communication.
Results
Quality escape detection lag
2-3 days → 18 minutes
Annual rework cost reduction
$93,000
Root cause accuracy
87% correct on first hypothesis
ROI payback
11 weeks
The Challenge
A mid-size discrete manufacturer was losing $200K+ annually to quality escapes and rework. Root cause analysis was manual, inconsistent, and lagged production by 2-3 days — by which time the defect had already propagated.
The Solution
We built a production intelligence layer that monitors machine sensor data, cross-references quality inspection results, and triggers anomaly alerts within minutes of a defect pattern emerging. The system generates root cause hypotheses ranked by historical probability, which a quality engineer reviews and approves before action is taken.
Timeline
8 weeks
Tech Stack
Want results like these for your operation?
Start with a 30-minute scope call. We'll define the baseline and project the ROI before any code is written.