SOLUTIONS/MANUFACTURING

Decisions for the world’s most complex plants.

From line-balancing on the floor to maintenance dispatch on the cell, MAIA reads every operational signal across your plants and decides faster than your shift leads can radio it in.

VERTICAL NOTEDesigned to integrate with the systems your plant already trusts, MES, SCADA, historian, CMMS, and HRIS. Connector scope is set during pilot kickoff against your stack, not promised in advance.
01 · WHY MANUFACTURING OPERATIONS BREAK

The signal exists. The decision doesn’t.

$50B
annual cost of unplanned downtime to global manufacturers
Siemens, 2024
23%
of production hours lost to changeover, micro-stops, and reactive maintenance
McKinsey
38 min
median time from anomaly signal to coordinated response on tier-1 floors
2,400+
operational signals an average plant generates per hour
02 · DECISIONS MAIA RESOLVES

Three decisions your operators stop waiting on.

USE CASE 01 · MFG-LINE-BAL

Rebalance a line before throughput slips

Signal
Cell L3-WLD spindle vibration trending out-of-band; downstream buffer projected to drain in 11 minutes.
Decision
Flex two operators from L4 to L3, drop takt by 4%, hold the line for 3 minutes for human accept, then auto-dispatch.
Writeback
MES schedule updated · Slack channel ops-mfg notified · audit chain D-... → S-... → R-...
USE CASE 02 · MFG-MAINT-DISPATCH

Dispatch a tech for a fault before the cell stops

Signal
Sensor anomaly on Press 7 sustained 14 minutes; pattern matches 9 prior dispatches that escalated.
Decision
Open a work order, dispatch the closest qualified tech (ETA 8 min), pre-stage the part from local stores, queue back-up cell.
Writeback
Maximo work order opened · ServiceNow incident · stores pick ticket
USE CASE 03 · MFG-CREW-COVER

Cover a shift gap before the cell stalls

Signal
Two certified welders flagged sick within the SLA window; cell L3-WLD throughput projected to drop 22% on the next bank.
Decision
Page three certified ops within reach, reweight overtime against forecast, hold the assignment for 4 minutes for human accept, then auto-dispatch.
Writeback
Workday shift created · MS Teams channel ops-mfg notified · audit chain D-... → S-... → R-...
03 · COMPLIANCE POSTURE

Built so your auditor doesn’t have to take our word for it.

Decision lineage
Every dispatch links signal → rule → confidence → human-on-loop, replayable for post-shift and auditor queries.
Tenancy isolation
Per-plant and per-business-unit tenancy; no cross-tenant inference, ever.
IATF 16949 / ISO 9001-friendly logs
Audit-grade logs aligned to your QMS reporting requirements; hand to your quality team without re-formatting.
OSHA / NIST data classification
Operational data classification and retention configurable per regulator.
04 · WHAT TO EXPECT FROM A PILOT

Forward-looking, not retrofitted. How a manufacturing pilot is scoped.

Scope
A typical manufacturing pilot covers one plant and two to three flows from {line balancing, maintenance dispatch, crew coverage, quality escalation}. We connect to your MES, CMMS, and HRIS via existing APIs and avoid touching your safety-critical systems of record beyond read-write fields agreed in the SOW.
Success criteria
Concrete, measured against your own baseline. Signal-to-decision under 200ms on in-scope flows in the sandbox. First production writeback to your MES or CMMS by week three. A measurable reduction in same-shift dispatch error rate, with the baseline you bring on day one.
Timeline
Week 1, connectors and tenancy. Weeks 2–3, sandbox decisions and first writeback to a non-production tenant. Weeks 4–8, expansion to two more flows. Weeks 9–12, production graduation review with your quality and IT leads.
First decision in production
Target, the first MAIA-authored decision lands in your MES or CMMS within 21 days of kickoff. We track this against the SOW and surface the milestone to both teams in real time.

MAIA is in pilot with a small number of design partners, by design. We do not publish anonymised partner outcomes here, the way many vendors do, and we will not invent ones. When we have an outcome we can name on a logo and attest to in audit, we will publish it. Until then, what you see above is how we structure the engagement, end to end.

Stop watching the cell stall. Start shipping decisions.

Request a Manufacturing briefing →See the sandbox