Your factory floor is full of data. Your decisions are still based on gut feel.
Manufacturers lose $50 billion a year to unplanned downtime alone. Metaoptic audits your operations — from the shop floor to the supply chain — and identifies exactly where AI will deliver ROI. No vendor bias. No vaporware. Just clarity.
Your AI challenge isn't technology. It's knowing where to start.
Unplanned downtime is bleeding your margins
Your maintenance team is firefighting, not preventing. The average manufacturer deals with 800 hours of equipment downtime per year — that's $50B in losses industry-wide. Predictive maintenance AI can cut unplanned downtime by 30-50%, but only if it's implemented against the right equipment with the right data.
Quality control can't keep up with production speed
Human inspectors catch 80% of defects on a good day. Computer vision AI catches 99.5%. But slapping cameras on your line without understanding your defect modes, lighting conditions, and production variability is how AI projects become expensive shelf-ware.
Your supply chain forecasting is still a spreadsheet
73% of manufacturers experienced supply chain disruptions in 2024. Your demand forecasting model — if you have one — probably uses last year's numbers plus gut feel. AI-driven demand sensing incorporates hundreds of signals in real-time.
Your OT and IT systems don't talk to each other
The average manufacturer runs 7+ disconnected software systems. Your ERP doesn't know what your SCADA system knows. Your quality data lives in paper checklists. AI can't help you until your data flows.
The ClearPath Method™ for Manufacturing
A structured approach that turns shop floor complexity into clear AI opportunities.
Illuminate
Shop Floor to Data Map
We walk your production floor, interview operators and managers, audit every system (ERP, MES, SCADA, CMMS), and map where your data lives, where it doesn't, and where AI can extract the most value. No generic questionnaires. Real observation.
Architect
Your AI Implementation Blueprint
We design a phased implementation plan prioritized by ROI and feasibility. Which line gets predictive maintenance first? Which quality checks can be automated? What data infrastructure needs to exist before AI can work? You get a concrete blueprint, not a PowerPoint dream.
Activate
Guided Implementation
We help you select vendors (without bias — we don't resell), manage the implementation, train your team, and validate results against your KPIs. When we leave, your team owns it.
What AI Actually Does on the Factory Floor
Predictive Maintenance for CNC Machines
Vibration and temperature sensors feed ML models that predict bearing failure 3 weeks in advance.
One mid-market precision manufacturer reduced unplanned downtime by 37% in the first 6 months.
Computer Vision Quality Inspection
AI-powered cameras inspect every unit at line speed, flagging defects human inspectors miss.
A food packaging manufacturer caught label misalignment 4x more reliably than manual inspection.
AI-Driven Demand Forecasting
ML models incorporating weather, economic indicators, and POS data for accurate predictions.
A building materials distributor reduced forecast error by 25%, freeing $2.3M in working capital.
Energy Optimization
AI-controlled HVAC and equipment scheduling based on production schedule and weather.
A plastics manufacturer cut energy costs by 14% in year one.
The Numbers That Matter
Based on published industry benchmarks from McKinsey, Deloitte, and manufacturer case studies.
Your machines are generating data 24/7. What if that data could tell you the future?
Stop evaluating AI vendors without a strategy. Start with clarity.
15-minute discovery call. No pitch. We'll tell you if AI makes sense for your operation.