Inspection, SPC, OEE, and predictive maintenance for small and mid-sized manufacturers. Built on the sensors and records you already have, and handed off for your team to run without us.
It starts with a free assessment, not an hourly meter. We look at your line and the data you already collect, and hand you a prioritized list of projects worth doing. Pick one and we write a proposal: the exact system, fully scoped at a fixed price you know before we start. No hourly billing, no retainer. When it ships it is yours: the code and the tool, branded as your own business, running on your systems and maintained by your IT. A clean handoff, with no lock-in and no recurring fees.
Your numbers live in ERP, MES, SCADA, and a stack of spreadsheets. Different units, different layouts, sentinels and subtotals mixed right into the data.
We pull from every source, unpivot and normalize it, drop the junk, and land one tidy feed your dashboards and databases can actually use, refreshed on a schedule, with nothing re-keyed by hand.
Three systems, 512 files a night, 18,440 rows unpivoted to tidy long format, 214 sentinels dropped, and pounds normalized to kilograms, with zero rows re-keyed by hand.
Point it at your exports and historians, map the fields once, and schedule the refresh. The clean feed lands where your boards and reports already look.
Manual inspection samples a fraction of production. Defects between samples reach the customer or the scrap bin.
Our model flags every defect on the web, classifies it, and traces each reject back to where it sits on the roll. You bring the camera; we build the detection and the analytics.
On the public NEU-DET steel-defect benchmark, this classifier scored 95% accuracy and 0.948 macro-F1 across six defect classes.
Your camera or integrator handles the mount. We train the model on your defects and wire the classified flags into your reject and marking systems.
A line runs slow and a new machine is on the quote. The lost capacity rarely shows up in the downtime report.
Break down availability, performance, and quality; rank the losses by dollars; and surface the micro-stops a standard downtime report never counts.
The largest loss was not breakdowns but unlogged micro-stops and slow cycles. That is 15.8 hours a week, worth $473,000 a year on this line.
Pull the event log from your PLCs or MES, build the OEE and loss analysis, and put the live board on a plant-floor screen.
Bearings and motors get replaced on a calendar, and still fail between intervals, usually at the worst time.
Monitor condition continuously, forecast remaining useful life, and schedule the repair on a planned stop instead of after a breakdown.
The model flagged a degrading spindle bearing six days before failure, enough lead time to order the part and swap it on a planned stop. Across five public run-to-failure datasets, these adaptive models cut prediction error 18–20% versus static baselines.
Add a vibration sensor, learn the asset's healthy baseline, and alarm on the trend. No new data-science team required.
A process shift surfaces on next week's report, after the out-of-spec product has already run.
Run control rules on every subgroup, detect a shift against a validated baseline, and alert the operator, the andon, or a phone.
A tool-offset drift was caught four minutes after it began, instead of surfacing on a report the following week.
Connect to your gauge or measurement data, set control limits on a good baseline, and route alerts to the right person while there is still time to correct.
Beyond project work, two products of our own, already in use and documented in full on the site.
Shift-handoff software for manufacturing. Operators file a structured end-of-shift report, supervisors approve it, and leadership gets one summary email at every shift change.
A free Python package for shop-floor SPC. Process capability, control charts, gage R&R, where every analysis checks its own assumptions and keeps a verifiable record of how it was computed.
pip install mfgqc
We look at the data your lines already collect and show you what is worth building, at no cost. You leave with a concrete plan, whether or not you hire us.
brantnersolutions.com