Deploy on one production line in 4 weeks. Prove ROI. Then expand.
AI-powered OEE dashboards, predictive maintenance, computer vision quality inspection, and MES integration for Ohio's manufacturing corridor. The AI tools that are transforming Industry 4.0 — built by engineers who understand the full stack from the SCADA system to the plant manager's screen.
Sound Familiar?
Problems we solve
Your MES doesn't talk to your ERP, and your SCADA doesn't talk to either.
You're tracking production schedules on spreadsheets and whiteboards.
Unplanned downtime is eating your margins and you can't predict it.
Manual quality inspection can't keep up with line speed — and you're shipping defects.
Your shop floor data lives in one system and your business data lives in another — and nobody reconciles them.
You've invested in sensors and equipment upgrades but you still can't see OEE in real time.
Capabilities
What we build
Real-Time OEE & Production Dashboards
Real-time visibility into machine status, throughput, OEE metrics, and quality yields — from SCADA to screen.
The plant manager who currently walks the floor with a clipboard and checks a whiteboard for shift status is our ideal client. We build real-time dashboards that pull data directly from your SCADA systems and PLCs — machine status, throughput rates, OEE metrics, and quality yields — all visible from a tablet or wall-mounted display. Deploy on a single production line in 4-8 weeks, prove the ROI, then expand plant-wide.
AI-Powered Predictive Maintenance
Machine learning models trained on your equipment data that predict failures before they happen — not just flag thresholds.
Unplanned downtime costs manufacturers an average of $260,000 per hour. We build AI models that go beyond simple threshold alerts — machine learning trained on your equipment's historical vibration, temperature, and cycle data to identify the subtle patterns that precede failures. From the vibration sensor on the machine to the prediction on the maintenance supervisor's phone — our team has built this full stack across multiple IoT and manufacturing deployments.
MES & ERP Integration — Bridging the OT/IT Gap
Custom middleware that connects SAP, MES, SCADA, and PLCs — without replacing any of them.
The biggest pain point in mid-market manufacturing: your operational technology and information technology are islands. SAP doesn't connect to your MES. Your MES doesn't talk to your SCADA. We build the middleware — custom APIs, OPC-UA connectors, data transformation layers, and real-time bidirectional sync — that bridges your OT and IT worlds without replacing either.
AI Quality Inspection
Computer vision defect detection at line speed — from single-camera setups to multi-station inline systems.
Computer vision systems that detect defects at speeds and accuracy rates human inspectors can't match. We've built inspection systems ranging from simple single-camera setups to multi-station inline systems. The result: fewer returns, less scrap, and quality data you can actually act on.
AI Supply Chain Intelligence
AI-driven demand forecasting, inventory optimization, and disruption prediction tied to your production schedule.
AI-powered demand forecasting models that predict order patterns with far greater accuracy than historical averages, inventory optimization algorithms that prevent both stockouts and overstock, and machine learning disruption detection that flags supply chain risks before they cascade into production delays. The models learn from your data and get more accurate over time.
Shop Floor Mobile Apps
Mobile-first tools for operators, inspectors, and maintenance crews — built for gloved hands and loud environments.
Mobile-first apps for operators, quality inspectors, and maintenance crews. Barcode scanning, digital work instructions, quality checklists, and downtime logging — replacing paper forms and clipboards with real-time digital capture that feeds your dashboards and analytics. Designed for gloved hands and loud environments.
The Difference
Why AppAxis
AI + IoT Expertise for Industry 4.0
Manufacturing's AI transformation is fundamentally an IoT and OT/IT convergence story — sensors, SCADA connectivity, data pipelines, AI models, and dashboards. Our engineering team brings deep experience building AI-powered manufacturing systems: computer vision inspection, predictive maintenance models, and demand forecasting — across multiple production environments.
Ohio Manufacturing Corridor
Ohio is the 3rd largest manufacturing state. Toyota, Honda, and GM all have Ohio operations. We're based in the heart of the tri-state manufacturing region and understand the businesses, the workforce, and the challenges unique to Midwest manufacturing.
Pilot-First Approach
We don't pitch multi-year transformation roadmaps. We deploy on one production line, prove 15-30% returns, and expand from there. Your plant keeps running while we prove the value.
You Own the Code
MES and IoT platform vendors lock you into per-device fees and proprietary systems. We build on your infrastructure, deliver your source code, and transfer full ownership. Your platform grows with your production, not your vendor's invoice.
Scenario
OEE Dashboard Deployment
Challenge
A mid-market manufacturer was tracking production output on whiteboards. Plant managers had no real-time visibility into machine performance or downtime causes.
Solution
We connected SCADA systems to a real-time dashboard, starting with one production line. OEE metrics, machine status, and quality data became instantly visible.
Result
15-30% improvement in unplanned downtime. Expanded to all production lines within 6 months.
Our Approach
How we work with manufacturers
Assessment
We start on your floor — your production lines, your MES and SCADA systems, your data gaps. What's connected? What isn't? Where does information die between the machine and the decision-maker? We map it before we propose anything.
Proposaltype
We deliver an interactive prototype built on your actual production data and workflows — not a slide deck with estimates. You see how dashboards render with your machine data, how alerts route to your maintenance team, how the system handles your edge cases. Your plant team pressure-tests it before committing to a full build.
Weekly Showbacks
During the build, you see working progress every week. Real data flowing through real pipelines. You steer the project with your feedback, not a change-order process.
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