8-18% Unplanned Downtime
Target range modeled from design-partner baselines - not yet independently audited
OPERATIONAL INTELLIGENCE
Own your output.
Connect your factory data, surface improvement opportunities, and verify every dollar of savings in a ledger your finance team signs.
Proof, not promises.
Operational and financial impact modeled with a repeatable, auditable methodology - so every stakeholder can trust what changed and why.
8-18%
Unplanned Downtime
5-12%
Scrap Reduction
10-14d
Time to First Win
Target range modeled from design-partner baselines - not yet independently audited
Illustrative line-level before/after, normalized for product mix
Modeled time from connector activation to first closed-loop savings event
5-12% Scrap Reduction
Illustrative line-level before/after, normalized for product mix
4-11% Throughput Gain
Modeled from shift-calendar and planned-maintenance normalization
10-14d Time to First Win
Modeled time from connector activation to first closed-loop savings event
Figures are illustrative model outputs from our design-partner program - not audited results or live telemetry. Every pilot ships a verified before/after report reconciled with your finance team.
Every number settles.
Live plant data arrives pending. It clears to a verified, finance-signed figure - the difference between a recommendation and a result. Illustrative close-out.
KaizenFlow - Savings ledgerillustrative
Changeover compression · Line 3
$134K
Scrap reduction
$383K
Throughput gain
$1.4M
Energy optimization
$113K
Verified savings
$2.0M
Live in two weeks.
From data connection to a closed-loop verified savings report - without replacing anything you already run.
Plug in. No rip-and-replace.
We sit on top of your current MES, SCADA, ERP, and historian stack. 43+ pre-built connectors - most plants are streaming inside an afternoon.
OPC-UAMQTTSAPIgnitionKepwareOSIsoft PI
Nine specialists, one queue.
A purpose-built ensemble of AI specialists analyzes every signal around the clock - surfacing anomalies, predicting failures, ranking opportunities by dollar impact and confidence.
Anomaly DetectionPattern MiningFailure PredictionConfidence Scoring
Close the loop. Sign-off ready.
Assigned actions, owners, deadlines. Before/after measurement reconciled against estimates. Finance gets a verified savings ledger - not a slide deck.
Verified Savings ReportAudit TrailFinance Reconciliation
Five stations, flagged and fixed.
From raw stock to final inspection - five stations, and for each one what the agent saw, the recommended fix, and the dollar impact. One illustrative line; the same loop runs on any process you connect.
Action needed
5-Axis CNC Center MC-12
CNC milling · titanium brackets
What the agent saw
Spindle vibration up +18% over 96h. Bore diameter trending 12 µm toward the upper tolerance limit; tool wear up 6%.
Recommendation
Replace the end-mill insert set within 7 days. Predicted tolerance breach in 11-14 days at current wear rate; saves ~620 parts/day from scrap.
Estimated impact$84K/yr
Healthy
Heat-Treat Furnace HT-04
Vacuum stress-relief · hardening
What the agent saw
Case-hardness uniformity tightened from ±4.5% to ±2.1% after the revised ramp recipe. Rockwell consistency up across the last 12 batches.
Recommendation
Roll the new ramp profile to furnaces HT-02 and HT-05 - projected rework reduction on each line.
Estimated impact$142K/yr
Healthy
Wash & Deburr Line WD-1
Ultrasonic wash · transfer conveyor
What the agent saw
Throughput steady at 1,420 parts/h vs nameplate 1,500. Bottleneck is downstream at the CMM queue (inspection backlog ↑).
Recommendation
Add a 2nd CMM fixture on 1st shift. Frees 80 parts/h of wash-line capacity = ~$9.6K/wk margin recovery.
Estimated impact$38K/yr
Watch
Robotic Assembly Cell AC-3
Robotic press-fit & fastening
What the agent saw
Fixture changeover takes 14 min on Mon/Wed shifts vs 6 min on others. Fastening-torque variance correlates with operator T-08.
Recommendation
Trigger micro-training: changeover SOP video + buddy-pair with a senior operator for 2 shifts. Expected reject rate -40%.
Estimated impact$26K/yr
Healthy
CMM / Vision Inspection FT-1
Coordinate measuring + vision
What the agent saw
Defect-detection model precision at 98.4% across part families. Drift detector predicts retraining needed in ~21 days as a new part format ramps.
Recommendation
Schedule auto-retraining on the last 30d of operator-validated inspection images. Zero labelling cost; keeps GD&T pass/fail accurate through the new ramp.
Estimated impact$12K/yr
Nine specialists, one queue.
Anomaly Sentry
Multi-method voting - Z-score, MAD, IQR, Isolation Forest - catches quality drift before it compounds into scrap or downtime events.
Z-SCOREMADIQRISOLATION FOREST
Throughput Analyst
Identifies bottleneck cells, calculates capacity utilization curves, and recommends sequencing changes that lift throughput without capex.
CAPACITY MODELINGBOTTLENECK ANALYSIS
Quality Sentry
SPC limits, Cpk monitoring, defect-to-process correlation. Surfaces the upstream signals predicting tomorrow’s quality holds.
SPCCPKDEFECT CORRELATION
Energy Optimizer
Demand-curve fingerprinting, peak shaving recommendations, idle-load detection. Cuts $/unit-output by trimming the hidden draw.
DEMAND CURVESPEAK SHAVINGIDLE DETECTION
Reliability Forecaster
MTBF prediction by asset class, failure-mode clustering, lead-time alerts. Converts unplanned events into planned interventions.
MTBFWEIBULLFAILURE MODE
Schedule Strategist
Changeover compression via SMED-aware sequencing. Re-orders the day to minimize setup loss without breaking promised dates.
SMEDSEQUENCINGSETUP MINIMIZATION
Yield Modeler
First-pass yield analytics, scrap-root attribution, rework cost rollup. Tells you which loss streams are worth the engineering hour.
FPYROOT-CAUSEREWORK COST
Maintenance Planner
Predictive intervals replace fixed schedules. Parts forecasting, technician load smoothing, and avoided-failure quantification.
PREDICTIVE INTERVALSPARTS FORECAST
Savings Auditor
Confidence-weighted before/after measurement, baseline normalization, finance reconciliation. The verified ledger CFOs sign off on.
BASELINE NORMCI-WEIGHTINGFINANCE RECON
Connectivity
43+ connectors, zero rip-and-replace.
We sit on top of the systems you already run. Sync your ERP, MES, SCADA, and IoT stack into one queryable plane.
Every plant. One queryable plane. 43+ connectors.
Connects natively with
ERP / BusinessSAPBusiness CentralNetSuiteOracle EBSInforEpicorSCADA / HistorianOSIsoft PIIgnitionKepwareFactoryTalkWonderwareGE Proficy
PLC / ControllersRockwellSiemens TIAMitsubishiBeckhoffOmronProtocolsOPC-UAMQTTModbusRESTODBC / SQLCSV / SFTP
This is what verified looks like.
Eight weeks in, every pilot lands on one screen - a finance-reconciled savings ledger, a live opportunity feed, and a run-rate you can take to the board. Not a slide deck. Here’s a representative plant.
KaizenFlow
Overview
▦Dashboard
◆AI Suggestions7
◬Anomalies2
Operate
⚙Connectors
◷Actions4
▤Savings Ledger
Kai · AI crew9 specialists · on
Dashboard
Illustrative demo · "Apex Dynamics - Plant 03" is a composite, not a customer
Plant 03 - Stamping
Last 24 hours
Live (12s ago)
MES Synced
SCADA Synced
SAP / ERP Synced
OSIsoft PI Streaming
Sandbox MQTT Demo
OEE %
82.3
2.7 pts to go · target 85
Throughput +9%
1,335units/hr
95% of target 1,400
Utilization +3.1%
78.4%
92% of target 85%
Scrap rate −12%
2.8%
80% of target 3.5%
Energy −4%
412kWh
79% of target 520
Opportunity queue · ranked by $ × confidence$285K open
01Changeover compression · Line 5Schedule Strategist$142K88% conf. · Route →
02Insert wear → tolerance breachAnomaly Sentry$84K92% conf. · Route →
032nd CMM fixture · 1st shiftQuality Sentry$38K81% conf. · Route →
04Idle air compressor · weekendsEnergy Optimizer$21K76% conf. · Route →
ActivityLive
Savings verified on Cell B changeoverfinance-signed · 4m ago✓
Vibration trending up on Spindle 7watch · 22m ago△
OPC-UA connector reconnectedsystem · 1h ago↺
Action closed: insert swap SOPOperator · 2h ago✓
Representative · Plant 03 / Cell B
A closed-loop ledger your CFO signs off on
OEE 82.3 +4.2%
Throughput 1,335 +9%
Scrap 2.8% −12%
Verified savings $134K finance-signed
Representative pilot · figures illustrative, verified per engagement
Return Modeling
Model the upside.
Drag the controls. Estimates use illustrative improvement ranges from our design-partner program - a starting point, not a promise.
15101520+
$10M$100M$250M$500M
5h50h100h200h
0.5%3%6%10%
Estimated Annual Savings - Median Range
$2.4M
Range: $1.3M to $3.4M annually
Downtime Recovery$546K
Scrap Reduction$383K
Throughput Gain$1.4M
Energy Optimization$113K
Conservative estimate · 8-18% downtime reduction · 5-12% scrap reduction · 4-11% throughput · 3-7% energy
Design-partner pilots include a verified before/after report at 8 weeks.
Answers, up front.
The questions every operations and finance team asks before a pilot.
How long does setup take?
You go live on your data in 1-2 weeks - we connect on top of your existing stack, no rip-and-replace. The full pilot runs 8 weeks and ends in a verified before/after savings report.
Do we need to replace our existing systems?
No. KaizenFlow sits on top of your current MES, SCADA, ERP, and historian stack via 43+ pre-built connectors.
What kind of ROI can we expect?
Our model targets 8-18% reduction in unplanned downtime and 5-12% scrap reduction in the first quarter; design-partner pilots produce a verified before/after report to confirm actuals.
Is our data secure?
Data is encrypted in transit (TLS 1.3) and at rest (AES-256), with multi-tenant isolation. Enterprise plans include private deployment.
Can we start small and scale later?
Yes - start with a single-facility pilot, prove ROI, then expand across the network.
How much of our team's time does it take?
No dedicated hire. We stand up and maintain the connections; your side is a one-hour weekly review during the pilot, plus the floor time to execute the improvements you choose. Steady-state, there is no server, historian migration, or report plumbing for your team to babysit.
How much data entry do operators have to do?
None to get OEE. KaizenFlow reads run, stop, rate, and quality signals from the systems you already have - MES, SCADA, PLCs, historians - so the numbers do not depend on operators logging codes at a terminal. Operator input is optional context, never the source of truth.
Is this monitoring machines, or monitoring people?
Machines and process. KaizenFlow prices losses by machine, line, shift pattern, and cause - it is not a time-and-motion tool, and it does not score individual operators. If you want employee surveillance, we are the wrong vendor.
Which plants are a good fit?
Plants that already log production somewhere - a PLC, SCADA, MES, ERP, or historian - and can grant read-only access to at least one line. Messy tags are fine; that is normal. If your floor is mostly pre-digital machines with nothing to read, a sensor-first tool like Guidewheel is the better starting point - see our honest comparison.
What payback period should we expect?
We do not quote a payback number - at design-partner stage we will not dress a model up as a track record. What we will do is show you the model. The ROI calculator takes four inputs: facilities, revenue per facility, unplanned downtime hours per month, and scrap rate. It then applies the modeled ranges, infers your hourly cost as revenue divided by an assumed 6,000 production hours per facility per year, and credits 35% of a recovered hour as margin. It does not subtract subscription cost, so what it prints is gross modeled savings, not payback. Put Pro pricing at $5k-15k per month against that figure yourself, and substitute your real hourly cost if 6,000 hours is wrong for your plant. Your pilot then replaces the whole model with measured numbers in eight weeks.
Engagement
Measure ROI before committing.
Every plan includes onboarding and a dedicated success engineer. Convert after your pilot and the full pilot fee credits toward your first year - terms confirmed before kickoff.
Pilot
$25k-$75k8-week engagement · scoped by lines & connectors
Measure the ROI in one facility before scaling to the network.
- 1 facility, 2 connectors
- Weekly ROI reviews
- Dedicated success engineer
- Verified savings report
- Fee credits to year one on conversion
★ Recommended
Pro
$5k-$15kper month · from $5k for a single facility
Full platform access with advanced analytics across your operation.
- Everything from your pilot, kept running
- Advanced TEEP analytics
- Reliability dashboards
- Cross-dept collaboration
- Audit trail & compliance
Enterprise
Customunlimited scale
Private deployment for regulated and multi-site operations.
- Unlimited facilities
- Private VPC deployment
- Custom connectors & SSO
- Dedicated CSM
- SLA commitments
Design-partner pricing - these are the rates we are quoting today, and yours are locked for your agreement term. Any adjustment happens at renewal with at least 30 days' written notice. No lock-in: either party can end the agreement with 30 days' written notice, and you leave with a full export of your data.
Pick a day.
Choose a weekday and a time that suit your team. We confirm by email within one business day - these are requests, not held calendar slots.
Own your output.
Connect your data. Surface opportunities. Get a verified savings report - in eight weeks.