Reporting & Analytics

Stop Guessing. Start Knowing.

Custom AI-powered reporting and analytics built for your factory floor, your systems, your data.

Industry Context

Manufacturing faces pressure from regulators, customers, and internal cost targets. Compliance reporting requirements are tightening, especially in automotive, aerospace, and pharma. Skilled labor shortages mean fewer people are available to manually compile and validate reports. Market volatility demands real-time visibility into production efficiency, waste, and throughput -- but most manufacturers rely on fragmented, delayed data from ERP, MES, PLCs, and spreadsheets.

By the Numbers

62%

of manufacturers lack real-time production analytics

Gartner Manufacturing Survey, 2025

25%

improvement in OEE with AI-driven analytics

McKinsey Smart Factory, 2024

$4.5M

average annual savings from predictive quality analytics

Deloitte AI in Manufacturing, 2025

The Problem

What you're dealing with

Spending 15+ hours each week manually reconciling production data from ERP, MES, and shop floor logs just to generate a weekly OEE report.

Discovering a quality deviation two days after it happened because batch records weren't updated in real time.

Can't meet ISO or FDA audit requirements because traceability data is siloed across six different systems.

Missing production targets because downtime and waste aren't visible until the end of the shift.

Watching engineers waste time building custom Excel macros that break every time someone updates a formula.

The Solution

How it works

We build a custom AI reporting system for your manufacturing environment. First, we use AI-driven interviews to map your actual data flows -- how people really work, not how the process is documented. We identify where data lives, how it moves, and where gaps or errors happen. Then we design a system that pulls data from your ERP, MES, PLCs, and other sources into a unified analytics layer. We use our proprietary platform to automate data ingestion, validation, and transformation. You get a dashboard that shows real-time OEE, quality metrics, downtime reasons, and material usage -- without manual effort. The system alerts your team to deviations as they happen, not days later. We deploy in weeks, not months, because our internal tooling speeds up development. You own the system; we don't sell subscriptions.

Arc

Automated data pipeline that ingests, cleans, and unifies manufacturing data from your ERP, MES, PLCs, and spreadsheets.

Wand

Custom analytics interface that delivers real-time dashboards, alerts, and drill-down reports for your operational needs.

In Practice

Before and after

Before

Every Friday, a production supervisor spends 8 hours manually extracting data from SAP, Excel trackers, and machine logs. They reconcile inconsistencies, calculate OEE and scrap rates, and email a PDF report to management on Monday morning.

After

We built a custom system that pulls data from SAP, MES, and PLCs every hour. The AI validates and aligns records in real time. Supervisors see live OEE, downtime reasons, and quality metrics on a dashboard. Management gets automated shift-end reports with drill-down capability.

1 AI interviews revealed manual data reconciliation was causing 12% error rate in weekly reports.
2 We designed a system to connect SAP, MES, and machine data streams with automated validation rules.
3 Built and deployed a custom dashboard showing real-time OEE, downtime, and scrap metrics.
4 Trained supervisors to use the system and set up alert thresholds for deviations.
5 Reports now generate automatically, and teams act on real-time data instead of historical summaries.

4 weeks

From discovery to deployed solution

For a mid-sized automotive parts manufacturer with SAP, MES, and 12 PLC data sources.

FAQ

Common questions

How do you handle integration with our legacy systems?

We connect to whatever you use -- SAP, Oracle, custom MES, PLCs, even spreadsheets. Our internal tooling is built for manufacturing data formats and protocols. If it speaks MODBUS, OPC UA, or has an API, we can work with it.

What about data security and compliance?

The system runs in your environment or a cloud tenant you control. We follow GxP, ISO, and SOC 2 standards as required. All data stays yours; we don't store or access it beyond the build phase.

How long does it take to get a working system?

Typically 4-6 weeks from discovery to deployed system. Our platform speeds up development, so we deliver faster than traditional software projects.

What if our processes change?

We design the system to be adaptable. You can modify dashboards, alerts, and data sources through a configurable interface. For major changes, we offer retainer support.

How is this different from buying a SaaS analytics tool?

SaaS tools are generic. We build exactly what you need -- connected to your systems, using your terminology, reflecting your workflows. You own it, and it works on day one because it's made for you.