All solutionsManufacturing systems and AI

Deadlines met and the cost of every part in hand

Work orders, master schedule, MRP and each machine's queue built with operations research. You promise the deadline the factory can keep.

Master schedule and MRP without spreadsheets
Optimized machine queues
Actual cost of every order

I want this for my company

Simulate my company

Does this happen to you?

If at least one of these happens in your company, it can be fixed.

I only find out an order is late when the customer calls

Planning lives in one person's head

Material runs out mid production while I have stock I don't need

I don't really know what each product costs

Real results

Real problems, real gains

Problems that happen in your industry, how they were solved and how much companies gained. Every number has a source for you to check.

The problem

Costly maintenance and machines stopping without warning.

How it was solved

AI predictive maintenance tracking the life of components.

The gain

45%

lower maintenance cost

Unilever factory in Indaiatuba, Brazil

Study · Fórum Econômico Mundial, Global Lighthouse Network, 2023

The problem

I can't see in real time how much each machine is producing.

How it was solved

Machine sensors send production data to the manager's tablet and phone.

The gain

22%

higher productivity on average

43 small and mid-sized factories in 24 Brazilian states, SENAI program

Study · Agência de Notícias da Indústria (CNI e SENAI), 2019

The problem

Too many defective tiles going into the kiln and becoming scrap.

How it was solved

Computer vision cameras reject bad tiles before the kiln.

The gain

68%

less scrap

VitrA Karo ceramic tile plant, Türkiye

Study · Fórum Econômico Mundial, Global Lighthouse Network, 2023

How it works

We map the factory

Products, BOMs, routings, machines and shifts.

We build the plan

Master schedule, MRP and scheduling rules that fit your reality.

We connect the shop floor

Tablet reporting and a factory TV dashboard.

We tune it with planning

We compare scenarios and improve the plan with the team.

What changes day to day

Reliable deadlines

Dates come from real capacity, right at the sale.

Right purchases

MRP says what to buy and when.

Factory in sight

Order progress and downtime in real time.

Real costs

What each part costs and where money leaked.

In practice

Before and after

The promised date is now the delivered date

Made to order furniture factory

Before

Parts lists made by hand, with wrong measures and missing hardware
Deadlines promised by eye, without seeing the cutting queue
Checking an order meant walking to the floor to ask

What we did

Designs become parts lists and routings, with optimized cutting plans
Scheduling by the real capacity of cutting, edging, drilling and assembly
Tablet reporting and an assistant that says where each order is

After

On time
orders ship as promised far more often: Less waste
of boards, with optimized cutting plans: Live
progress of every order, without walking to the floor

Typical scenario created to show how the solution works day to day. The numbers give a sense of scale, and each company's gain is measured together during the project.

What it can include

Production planning and control built by a production engineer: work orders, master production schedule, MRP, machine scheduling with operations research, shop floor, quality and costs, with AI at every step.

Work orders
Master schedule (MPS) and MRP
Detailed machine scheduling
Shop floor reporting
OEE and maintenance
Quality and traceability
Costs and tax reporting

Every feature

Orders and product engineering

Work order created straight from the sales order
Multi-level bill of materials with versions
Routing with steps, machines and standard times
Custom products built from a base model
Order status visible to sales and production
Order on a tablet with drawings and work instructions
AI suggests BOM and routing from similar products

Planning and master schedule

Weekly master schedule combining firm orders and forecast
MRP calculates what to buy and what to make
Accounts for stock, open orders and incoming purchases
Minimum lot, safety stock and lead time per item
Capacity check before promising a date to the customer
Simulation: what if a big order comes in?
AI demand forecast from history and seasonality

Detailed machine scheduling

Finite capacity sequencing by machine, shift and operator
Priority by due date, slack or customer
Less setup time by grouping similar orders
Drag and drop Gantt chart
Fast replanning when a machine stops or material is missing
Operations research optimization to cut delays and idle time
This week's bottleneck flagged in advance

Shop floor, OEE and maintenance

Reporting on tablet, phone or barcode scanner
Start, pause and finish each step with one tap
Downtime reason logged on the spot by the operator
OEE per machine: availability, performance and quality
Factory TV dashboard with order progress
Preventive maintenance by calendar, hours or cycles
AI reads sensors and warns before a breakdown

Quality and traceability

Inspection plan at receiving, in process and final
Measurements entered on a tablet during production
Lot tracing: raw material used and customer who received it
Nonconformities with cause and corrective action
Rejected lots blocked automatically in stock
Computer vision cameras to find visual defects
AI spots scrap patterns by machine, shift or supplier

Purchasing, stock and subcontracting

Purchase suggestions from MRP, ready to approve
Quotes with price and lead time history per supplier
Stock by lot and location, with scanner counts
Material reserved for each work order
Shipments, returns and balances at subcontractors
Contract manufacturing for other companies
Alerts for materials about to run out and idle stock

Costs and tax

Standard cost per product from BOM and routing
Actual cost per order: material, labor and machine
Standard versus actual showing where money leaked
Margin by product, customer and order
Sales, shipment and return invoices integrated with production
Tax production reports fed by shop floor data
Monthly stock and cost closing without side spreadsheets

AI in production

Ask in plain language: what is late today and why?
Daily production summary on WhatsApp or email
Alerts for unusual consumption, scrap or times
New sequence suggested when a rush order comes in
Explains the plan: why this order comes before that one
Warns of delay risk before the customer notices
Important decisions always go through your approval

Frequently asked questions

No. The production system connects to the ERP and tax tools you already use.

Shall we see how this looks in your company?

Tell me how your operation works today. In a quick conversation I'll show you where to start.

I want this for my company

Simulate my company

We map the factory

Products, BOMs, routings, machines and shifts.

We build the plan

Master schedule, MRP and scheduling rules that fit your reality.

We connect the shop floor

Tablet reporting and a factory TV dashboard.

We tune it with planning

We compare scenarios and improve the plan with the team.

The promised date is now the delivered date

Made to order furniture factory

Before

Parts lists made by hand, with wrong measures and missing hardware
Deadlines promised by eye, without seeing the cutting queue
Checking an order meant walking to the floor to ask

What we did

Designs become parts lists and routings, with optimized cutting plans
Scheduling by the real capacity of cutting, edging, drilling and assembly
Tablet reporting and an assistant that says where each order is

After

On time
orders ship as promised far more often: Less waste
of boards, with optimized cutting plans: Live
progress of every order, without walking to the floor

Typical scenario created to show how the solution works day to day. The numbers give a sense of scale, and each company's gain is measured together during the project.