Alien.fi — Consultancy

OAKRIDGE_

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Manufacturing · 10 months

Oakridge Industrial

Tier-1 auto supplier · 4 plants · 2,400 employees

IndustryManufacturing

EngagementCustom + Managed

Duration10 months

Team8 alien.fi · 6 client

StackPyTorch · OPC-UA · Edge GPU · Snowflake

Case Study

PREDICTIVE MAINT
CUT DOWNTIME
34%

A vibration-and-vision predictive maintenance program plus CV-based quality control across four high-mix manufacturing plants.

34%

Less downtime

Unplanned only

+18%

Throughput

Across 4 plants

-67%

Defect escapes

Customer claims

3.2×

First-year ROI

Payback in 6 months

The challenge

BREAK-FIX TREADMILL

Oakridge ran a break-fix maintenance shop. A single CNC failure could halt a production line for 14 hours. Their largest OEM customer threatened to dual-source after three quality escapes in one year.

An attempted IIoT rollout from a big-box vendor had stalled at proof-of-concept for 18 months.

14 hr

Avg unplanned down

3

Quality escapes/yr

$8.4M

Lost throughput cost

The approach

FOUR PHASES

Sequenced for cash-flow positive value at every milestone. Each phase paid for the next.

Phase 1

Wks 1–8

Data + Sensors

Audit of 240 critical machines. Retrofit vibration + temperature sensors. Standardized OPC-UA streaming to edge boxes.

Sensor retrofit

OPC-UA streams

Edge gateways

Data lake

Phase 2

Wks 9–22

Predictive Maint

Per-asset failure models. Maintenance scheduler integration. CMMS work-order auto-creation.

Failure models

Scheduler

CMMS hooks

Reliability KPIs

Phase 3

Wks 23–34

CV Quality Control

Edge GPU camera systems on 8 critical inspection points. Defect classifier with active-learning loop.

Camera rigs

Defect classifier

Active learning

SPC dashboard

Phase 4

Wks 35–40

Plant-by-plant Rollout

Standardized playbook deployed across remaining three plants in 6 weeks. Internal AI guild seeded.

Rollout playbook

AI guild

Training library

Reliability QBRs

We've worked with three IIoT vendors over a decade. alien.fi was the first to actually shut up and listen on the plant floor. The maintenance team trusts the alerts — that's everything.