End Downtime.
Elevate OEE.
AI Supervisor unifies data from every machine — preventing downtime before it starts.
The Hidden Cost of Downtime
Manufacturers typically lose 5-20% of productive capacity to unplanned downtime. Each hour of stoppage costs thousands in lost production and fixed overhead.
Machine health signals exist across heat, vibration, and current draw—but they're scattered, inconsistent, and rarely acted on fast enough. Investigations happen after failures, not before them.
An Intelligence Layer for Every Machine
AI Supervisor doesn't replace your systems. It unifies them — creating a continuous awareness layer that learns from every signal.
Unified Data Stream
Connects heat, vibration, current draw, and line rate signals into a single, coherent intelligence layer.
Continuous Awareness
Real-time monitoring exposes patterns invisible to manual inspection, catching failures before they cascade.
Actionable Intelligence
Every operator action feeds back into the system, refining thresholds and reducing false positives.
The ABB Wood Transformation
Brazil's largest pallet lumber manufacturer producing over 60,000 cubic meters monthly faced a critical challenge: unpredictable downtime was costing millions.
Challenge
The core issue was not mechanical. Machine health signals existed across heat, vibration, current draw, and line rate, but they were scattered, inconsistent, and rarely acted on fast enough.
Supervisors relied on instinct and manual logs. Operators were flooded with low-value alerts while missing early indicators of real failure. ABB experienced two major equipment stoppages per week and hundreds of micro-stops that compounded into significant lost output.
Implementation: Built on ABB's Own Standards
The AI Supervisor was trained on ABB's internal manuals, standard operating procedures, and over 30,000 historical downtime records.
This ensured every recommendation aligned with how the plant already operated.
Because the intelligence was built on ABB's own rules, supervisors trusted every alert. Operators saw corrective instructions written in the same terminology used in their SOPs.
Our AI wasn't a replacement for human expertise, but an amplifier.
Results
Unplanned failures dropped sharply, uptime stabilized close to 80 percent, and total downtime costs fell by more than $8,000 per week.
| Metric | Before | After | Improvement |
|---|---|---|---|
| Overall Equipment Effectiveness (OEE) | 39.7% | 72.1% | +32.4 percentage points |
| Mean Time Between Failures | 18 hours | 26 hours | +44% increase |
| Average Unplanned Downtime per Week | 12.5 hours | 6.8 hours | -46% reduction |
| Operator Response Speed | — | 2x faster | Earlier intervention and fewer escalations |
| Production Yield Quality | 91% | 98% | +7 points |
Anticipation beats reaction.
Monitoring signals in real time exposed patterns no one could see before.
Grounded intelligence builds trust.
Training on the plant's manuals and SOPs made the system usable from day one.
People are the multiplier.
The technology succeeded because it made operators and supervisors more effective, not redundant.
People as the
Multiplier
Technology amplifies expertise. Operators make better decisions faster. The floor runs with confidence.
For Every Line, Every Industry
This intelligence layer fits anywhere data exists. From automotive assembly to pharmaceutical production, AI Supervisor adapts to your operations.
Bring Zero Downtime to Your Factory
See how AI Supervisor transforms data into uptime.