How do you integrate with our existing MES and ERP systems?
We build on top of your existing systems — SAP, Oracle, Epicor, Infor, or whatever you run. The AI layer connects via API, database, or file-based integration. We don't replace your MES or ERP. We automate the manual steps that happen between systems — the copy-paste, the re-keying, the reconciliation your team does every shift.
What does my floor team do differently on day 1?
Almost nothing. The first workflow runs alongside your existing process — AI processes production data in parallel while your team works normally. Once accuracy is validated (typically 2-3 weeks), we switch over. Your floor managers start managing exceptions instead of filling out forms. The transition is gradual, not a big bang.
How do you handle the variety of equipment and data formats across our plant?
Every plant is different — different equipment, different PLCs, different data formats. Our engineers spend the first 2 weeks inside your operation, mapping every data source and format. The AI learns your specific equipment outputs, sensor formats, and naming conventions. When it encounters something new, it flags it for review and learns from the correction.
What happens during a system outage or network issue?
Every workflow has fallback procedures. If connectivity drops, data queues locally and syncs when the connection returns. Your team can always revert to manual processes — we don't create single points of failure. The AI layer is designed to be additive, not a dependency your operation can't function without.
How do we measure ROI on plant automation?
We define metrics with you before building anything. Typical plant metrics: production logs completed per shift, data entry hours eliminated, quality hold resolution time, OEE accuracy, and scrap reduction from earlier defect detection. We set up dashboards showing before/after in real-time. If the numbers don't improve within 90 days, we fix it on our dime.
What's the total cost for year 1?
Two options. Per Workflow: $25K-$75K per workflow, best for starting with one high-impact process like production logging or quality data capture. Dedicated Team: ~$22K/month for 2+ AI engineers embedded in your operation, building multiple workflows continuously. Most plants start with one workflow, prove the ROI, then move to a dedicated team. Every engagement starts with a free 30-minute assessment — no commitment.