ManufacturingWhat we do for manufacturers, and a client case
Manufacturing can be improved massively, in output and in quality.
We map how orders, machines and quality really run from the plant’s own data, measure the gap to best practice, and check every process as it happens.
Our manufacturing clientsPlants we have worked inside
Manufacturers who work with us.
What a manufacturer can gainPublished results, with their sources
The gains are documented.
85%
world-class OEE, vs ~60% typical: every loss mapped and owned
Nakajima, “Introduction to TPM,” Japan Institute of Plant Maintenance
10–30%
higher throughput where Industry 4.0 is done right
McKinsey, “Capturing the true value of Industry 4.0,” 2022
15–30%
higher labor productivity: manual work taken out of the loop
McKinsey, “Capturing the true value of Industry 4.0,” 2022
10–20%
lower cost of quality with live, digital quality control
McKinsey, “Industry 4.0: How to navigate digitization of the manufacturing sector,” 2015
What manufacturers needOn time, audit-ready, safe
Built for how plants really run.
On-time delivery
Orders shipped when promised, bottlenecks found early.
Audit-ready quality
Evidence for every unit, ready in a day, not weeks.
Safer floors
Danger-zone entries and near misses tracked live.
Low-risk start
One plant, 10 weeks. Runs on-prem with open-source models.
Case in pointExplosion-protected equipment manufacturer, Istanbul
$10.7–11.3M saved a year.
Results at month 12. On time, every unit audit-ready, safer floors.
75% → 95%
on-time delivery
Measured by the client: May–Oct 2026 vs the 12 months to Dec 2025
3 weeks → 1 day
audit evidence prep
Measured by the client
4.8 → 0.9
danger-zone entries per 1,000 hours
Measured by the client, against a four-week shadow baseline
How we got thereThe Five Step Method in the plant
From the plant’s own data to live checks on every process.
Step 01: Collecting Data
Connect ERP, CRM and other systems; capture hidden work in Excel, e-mail and chat; add embedded data and live camera feeds
Step 02: Mapping Processes and Data Flow
Map processes as they really run; map the strategy behind them; trace the data supply chain
Step 03: Gap Analysis
Measure the gap to best practice; surface major red flags in processes and data flow
Step 04: Optimal Design
Design optimal processes and data flow; build the transformation playbook
Step 05: Implementation Live Assurance
Run live QC on every process and data flow; reject and QA flagged processes and data; score the enterprise in real time against the optimal design