Stop Guessing on Production Efficiency Track KPIs with Real-Time Precision
Imagine slashing downtime by 30% and boosting output by 25% through dashboards that pull data from your shop floor sensors, ERP, and inventory systems—no more chasing numbers across spreadsheets.
Join 150+ businesses with crystal-clear production insights
The "Data Silo" Problem
Scattered shop floor data from PLCs and sensors leading to unplanned downtime on assembly lines
Inaccurate inventory tracking of raw materials like rebar and aggregates causing overstock and waste on job sites
Delayed quality control reports on weld inspections and material tests delaying shipments to construction sites
Manual yield calculations for batch mixing and fabrication eating into shift time on the shop floor
Fragmented supplier performance metrics for steel deliveries and component sourcing slowing procurement for projects
Unseen equipment maintenance needs for cranes and CNC machines risking breakdowns during critical pours or runs
AI-Powered KPI Tracking That Fits Your Factory Floor
We've built dashboards for manufacturers handling everything from automotive parts to heavy machinery, drawing on field-tested integrations that withstand the rigors of 24/7 operations.
Why Choose Us
Let's be honest, in manufacturing, you're dealing with machines that don't wait and teams that need answers fast. Our custom KPI tracking platform at AIQ Labs pulls data from your PLCs, MES systems, and ERP into one unified view. No more flying blind through production runs. We engineer it from the ground up, ensuring it scales as your output grows. Here's the thing: this isn't off-the-shelf software pieced together. It's a robust system you own, designed to deliver actionable insights—like alerting you to a 15% drop in cycle time before it impacts your quota.
What Makes Us Different:
Unlock Production Power with Clear Visibility
Real-Time Downtime Detection
Real-Time Downtime Detection: Catch issues like a jammed conveyor or hydraulic failure in concrete pumps early, reducing unplanned stops by up to 40%. You're probably thinking about last month's surprise breakdown that cost you a full shift—our dashboards flag it instantly via IoT sensors, so your team fixes it before the line grinds to a halt or a pour is ruined.
Optimized Inventory Flows
Optimized Inventory Flows: Track raw material usage like lumber and steel against production schedules and project timelines, cutting excess stock by 25% and freeing up capital. Think of it like building a bridge: you don't pour concrete without knowing the load. Our system ensures you order just enough rebar or fabricated parts without shortages derailing your builds or assembly runs.
Informed Decision-Making on Yields
Informed Decision-Making on Yields: Monitor defect rates in welding and overall equipment effectiveness (OEE) live, boosting throughput by 20%. In the heat of a production push or site installation, data silos are like faulty blueprints—our platform provides the clear view to adjust processes on the fly, ensuring consistent yields for structural components or machined parts.
What Clients Say
"Before AIQ's dashboard, we were piecing together shift reports from our ERP, MES, and floor sensors, and it took hours. Now, our OEE is visible in real time across the plant, and we've cut scrap waste from 8% to under 4% in just three months on our gear hobbing lines. It's like having an extra supervisor who never sleeps."
Mike Harlan
Plant Manager, Precision Gear Manufacturing Inc.
"Our old setup meant guessing on tool wear for our CNC mills, leading to breakdowns every other week during high-volume runs. This KPI platform integrates our machines directly with CMMS alerts—we've extended maintenance intervals by 50% without risking output on precision components. Finally, data that works as hard as our crew."
Sarah Kline
Operations Director, Industrial Components Fabricators Ltd.
"We handle custom orders for automotive suppliers, including stamped metal parts, and tracking cycle times manually was a nightmare with our punch presses. AIQ built us a dashboard that pulls from our ERP and floor sensors, helping us shave two days off lead times for just-in-time deliveries. ROI was clear in the first quarter—no hype, just results on the shop floor."
Tom Reyes
VP of Manufacturing, Apex Metalworks & Fabrication
Simple 3-Step Process
Discovery and Mapping
We dive into your production processes, identifying key KPIs like cycle time and defect rates, then map how your current systems—like ERP and sensors—feed into a unified dashboard.
Custom Build and Integration
Our engineers construct the platform using your data sources, testing integrations to ensure real-time accuracy without disrupting your lines.
Deployment and Training
We roll it out with hands-on training for your team, then monitor performance to tweak for peak efficiency as your operations scale.
Why We're Different
What's Included
Common Questions
How does this KPI platform integrate with my existing manufacturing software?
We start by auditing your setup—think ERP like SAP or Oracle, MES systems such as Epicor, and even legacy PLCs on the shop floor. Our custom integrations use secure APIs to pull data in real time, creating a single pane without disrupting operations. For instance, in a recent project for a parts manufacturer, we linked their inventory system to production sensors, updating KPIs every 15 seconds. It's all built to your specs, so no clunky middleware. And since we own the code, we handle any updates as your tools evolve. This means less downtime chasing data and more time optimizing your lines. You're looking at a system that feels native, not bolted on.
What specific KPIs can we track for our manufacturing operations?
Tailored to your setup, we focus on core manufacturing metrics like Overall Equipment Effectiveness (OEE), first-pass yield, cycle time variance, and scrap rates. For a welding shop, that might include arc time efficiency; for assembly, it's takt time adherence. We pull from your sensors and logs to show trends—say, how a machine's vibration correlates with defects. One client tracked downtime causes across shifts, identifying a 20% improvement from better shift handoffs. It's not generic; we map exactly what drives your ROI, like material utilization in high-volume runs. Short answer: whatever keeps your production humming, visualized clearly.
Is this platform scalable as our manufacturing business grows?
Absolutely, designed for growth from single-line SMBs to multi-plant operations. Our enterprise-grade architecture uses modular cloud infrastructure that scales horizontally—add data sources or users without performance dips. We've built for manufacturers expanding from 50 to 500 employees, handling spikes like seasonal surges in output. Unlike rigid tools, ours adapts: integrate a new CNC line? We code it in. No limits on data volume or concurrent views. Here's the thing—you're investing in a system that grows with you, avoiding the costly rip-and-replace later. Field-tested to support 24/7 ops without breaking a sweat.
How secure is the data in your KPI tracking dashboards?
Security is non-negotiable in manufacturing, where data means competitive edge. We use end-to-end encryption for all transmissions, role-based access controls so floor leads see only line metrics, and compliance with standards like GDPR and ISO 27001. Data stays in your controlled environment— no third-party clouds unless you choose. For a recent auto supplier client, we implemented audit logs tracking every dashboard access, preventing unauthorized views during sensitive prototype runs. Regular vulnerability scans and our in-house engineering ensure it's robust against threats. Think of it as fortifying your digital factory walls: safe, reliable, and always up.
What's the timeline to get our custom KPI dashboard up and running?
Typically 6-8 weeks from kickoff to live deployment, depending on your system's complexity. Week 1-2: discovery, mapping your KPIs and data flows. Weeks 3-5: building and integrating with your ERP or sensors. Final weeks: testing on a pilot line, training, and go-live. We moved a mid-sized fabricator from concept to tracking full plant OEE in under two months, with minimal disruption. It's iterative—we prototype early so you see value fast. Post-launch, we monitor for a smooth handoff. No endless delays; we're builders focused on getting you results quickly.
Can this work for our specific manufacturing niche, like custom fabrication?
Yes, we specialize in niches like yours—custom fab shops with variable runs and tight tolerances. Our dashboards adapt to track bespoke metrics, such as job-specific yield or material waste per blueprint. For a steel fabricator we worked with, we customized views for weld quality and cut efficiency, integrating CAD data with shop floor IoT. It handled their one-off projects without generic assumptions. We understand the pains: fluctuating orders, skilled labor shortages. Our approach ensures the platform fits your workflow, delivering insights that boost margins on those high-value custom jobs. Let's chat about your setup.
Ready to Get Started?
Book your free consultation and discover how we can transform your business with AI.