Process Discovery

Stop Guessing How Your Factory Really Works

We build custom AI systems that map your actual processes, not the documented ones.

Industry Context

Manufacturing faces pressure from regulatory compliance, supply chain volatility, and an aging workforce. Documentation often lags reality as operators develop workarounds for outdated procedures. New hires struggle to learn unwritten rules, while audits reveal gaps between official SOPs and actual practice. Without accurate process maps, continuous improvement initiatives stall and quality deviations go unexplained.

By the Numbers

75%

of production inefficiencies go undetected

Deloitte Manufacturing Survey, 2024

18%

of production costs from hidden process waste

McKinsey Operations, 2024

10 days

to map a full production line with AI

Gartner Smart Manufacturing, 2025

The Problem

What you're dealing with

Quality audits uncover deviations from documented procedures, but no one can trace why or how they happen.

Experienced operators retire, taking tribal knowledge of process adjustments and failure workarounds with them.

Cycle time targets are missed consistently, but time studies can't pinpoint the hidden bottlenecks.

New product launches hit snags because production assumes steps that aren't in the official workflow.

Regulatory submissions require process validation, but the as-built process doesn't match the as-designed one.

The Solution

How it works

We start by running AI-driven interviews with your operators, engineers, and quality staff. Our system listens to how people describe their work, identifying gaps between official documentation and actual practice. We then design a custom AI model that maps your real process flows, including exceptions, decision points, and informal handoffs. Using our proprietary platform, we build a digital twin of your manufacturing process that updates in real time as conditions change. You get a live system that visualizes workflows, flags deviations, and recommends optimizations based on actual data -- not assumptions. The entire delivery takes weeks, not months, because our internal tooling automates the heavy lifting of data integration and model training.

Atlas

Runs automated interviews with your team to capture real process steps and exceptions

Arc

Builds and deploys a custom digital twin of your manufacturing process that updates in real time

In Practice

Before and after

Before

Operators manually log deviations on paper forms. Quality engineers spend days correlating logs with ERP data to investigate root causes. Process improvements are based on outdated value stream maps.

After

We built a custom AI system that continuously monitors operator actions, machine signals, and quality data. It flags process deviations automatically, suggests probable causes, and updates the digital process map in real time. Quality teams now resolve issues in hours, not days.

1 AI interviews operators to capture real workflow steps
2 System connects to PLCs, MES, and quality databases
3 Digital twin visualizes actual process flow with live data
4 Alerts trigger when deviations exceed configured thresholds
5 Teams use AI-generated insights to implement corrective actions

6 weeks

From kickoff to live system

For a mid-sized automotive parts manufacturer with mixed legacy and modern equipment

FAQ

Common questions

How do you access our sensitive manufacturing data?

We work within your IT environment. Data never leaves your network. Our tools connect to your systems via secure APIs and on-premises deployments.

What if our processes change after you deliver the system?

The system adapts automatically. It keeps learning from new data and operator inputs, so it stays current without re-engineering.

How is this different from off-the-shelf process mining software?

Off-the-shelf tools assume your data is structured and labeled correctly. We build a custom system that works with your actual data -- messy, unstructured, scattered across systems -- without requiring you to reformat everything first.

What kind of team involvement is required during implementation?

We need 2-3 hours per week from key operators and engineers for interviews. IT support is needed for system integration. Beyond that, we handle the build.

How do you ensure the solution works with our legacy equipment?

Our platform is built to interface with older systems -- from paper logs to PLCs. We've built systems for facilities with equipment dating back to the 1980s.