Intersect AI
INDUSTRIES · MANUFACTURING

AI for manufacturers, working on the plant floor.

Downtime, scrap and late orders all show up first in data your plant already produces, spread across the ERP, MES, SCADA and a lot of spreadsheets. We find where AI pays back first, then build the models and agents that put it to work on the line.

Senior consultants on every projectPrices in AEDArabic and English
EXAMPLE · VISION INSPECTIONPackaging plant, line 3Live
Inspected this shift4,812 Rejected at the station17 Line speed120/min
08:14Seal misaligned, unit removed at station 4Rejected
08:21Label 2° off square, inside tolerancePassed
08:30Three seal faults in ten minutes on capper 1To maintenance

An example vision inspection model with example figures.

Defects caught at the stationMaintenance planned from vibration dataProduction plan rebuilt when a supplier slipsShift report written from the MESPurchase orders matched to invoicesSpare parts reordered before they run outEnergy per unit tracked by lineQuality certificates read and filedCustomer order emails into the ERPSafety observations logged from photos
Mikael KreugerMax DoyleDr John HawkinsDavid Gnanapragasam You'll speak to the senior team from the first call.
Claude Partner Network Certified Services Partner badge Intersect AI is Certified in the Claude Partner Network Services Track.
WHERE THE HOURS GO

Plants run on more data than anyone has time to read.

The information that would prevent most stops and scrap usually exists already. It sits in systems that were never connected, read by people who are busy running the line.

TODAY

Data spread across six systems

ERP, MES, SCADA, historians, spreadsheets and clipboards. Each holds part of the story, and nobody sees it together until the monthly review.

AFTER THE BUILD
ERPMESSCADAOne production view
One view of output, downtime and scrap, refreshed every few minutes, that planners and supervisors both trust.
TODAY

Breakdowns found when the line stops

Maintenance runs on the calendar and on whoever hears the noise first. Unplanned stops still cost whole shifts.

AFTER THE BUILD
SensorsFailure predictedWork order
Vibration and temperature watched around the clock, with a work order raised days before a likely failure.
TODAY

Defects caught at the end of the line

Quality checks sample a few units per batch. By the time a fault shows up, a pallet of scrap is already made.

AFTER THE BUILD
CameraUnit rejectedLine lead told
A camera checks every unit at the station, and the line lead sees the fault while it can still be fixed.
WHERE AI HELPS IN MANUFACTURING

Where AI pays back on the plant.

Four areas cover most of what we build for manufacturers, plus the paperwork that sits around them.

Operations and production intelligence

Output, downtime and scrap from every line in one place, with the reasons written up before the morning meeting.

Predictive maintenance and asset health

Sensor data read continuously to predict failures, so the work happens on a planned stop.

Quality, yield and defect prevention

Vision models trained on your own products catch defects at the station, with root cause analysis on the ones that get through.

Production planning and scheduling

Plans rebuilt when orders, materials or machines change, with the trade-offs laid out for the planner to choose.

Supply chain and inventory

Demand forecasts, supplier lead times and stock levels combined, so you hold less stock and run out less often.

Supplier and quality paperwork

Invoices, delivery notes and quality certificates read, matched to the order and filed where auditors can find them.

MAINTENANCE AND QUALITY

Know which machine needs attention this week.

A model trained on your sensor history scores the health of each asset and explains the score. Planners see it beside the production schedule and book the work into a planned stop.

Asset health · Line 3 Example figures
OEE today78%
Unplanned stops, this month3
Units inspected, this week48,210
Open work orders12
ASSET HEALTH · LINE 3
Filler 2Filling92Healthy
Capper 1Capping41WatchWO-3318 raised
Conveyor C3Transfer76Healthy
Labeller L1Labelling88Healthy
VIBRATION · CAPPER 1 · LAST 30 DAYS Alarm levelBearing likely to fail in about 6 days

An example maintenance dashboard with example figures.

YOUR SYSTEMS

Built on the systems your plant already runs.

Models read from the ERP, MES, SCADA and historian you already have, and push results back to where planners and supervisors work.

ERPSAP, Dynamics, NetSuite
MESProduction records
SCADA and historianSensor data
CamerasAt the station
Agents and models Built by Intersect AI around your lines
Work orders raised
Plan updated
Quality alerts
Shift report written
HOW WE WORK

How a manufacturing project runs.

Discover, develop, deploy. The same team does all three, so whatever we recommend has to survive a real shift.

Talk to an AI expert
  1. 01DISCOVER

    Discover

    On the floor with production, maintenance, quality and planning, counting where hours and margin go.

    AI Consulting
  2. 02DEVELOP

    Develop

    Models trained on your own sensor history, images and orders, then tested against last quarter’s real events.

    AI Development
  3. 03DEPLOY

    Deploy

    Running beside the line, with supervisors trained and a person approving its decisions for the first weeks.

    The 90-day programme
PRICING

Three ways to start, priced in AED.

Most manufacturers start with one model or the 90-day programme. Every project begins with a call, so the starting price you see here is close to the number you get.

Get a quote
SINGLE AGENT BUILD FromAED 55,000

One agent that takes a whole job off your team, connected to the tools you already use. Live in around five weeks.

See agent builds
90-DAY AI AGENT ENABLEMENT PROGRAMME FromAED 110,000

Discovery across the business, then several agents built and live inside 90 days. Our most common starting point.

See the programme
ENTERPRISE AND CUSTOM Talk to us

Enterprise discovery projects start from AED 250,000. Custom AI development is quoted per project after scoping.

Enterprise AI Consulting
OUR WORK

What clients say once it's live.

VERITA · DATA CAPTURE AND AI
“Intersect AI learned our complex procedures and found non-intrusive ways to capture the data, so we can finally apply AI to deliver better patient outcomes.”
Julian AndrieszCEO, Verita
QUESTIONS

AI in manufacturing: what plant managers ask us

Do we need new sensors or cameras?

Often not. Most plants already collect more data than they use. Where a vision model needs a camera at a station, we specify an off-the-shelf one and fit it around the line.

Which systems do you work with?

SAP, Microsoft Dynamics, Oracle NetSuite and other ERPs, most MES and SCADA platforms, historians, and the spreadsheets that fill the gaps between them.

How much does it cost?

A single agent starts from AED 55,000 and the 90-Day AI Agent Enablement Programme from AED 110,000. Custom models, such as vision inspection or failure prediction, are quoted per project after scoping because they depend on your data and equipment.

Does it run on site or in the cloud?

Wherever you need it. Vision models often run on a small computer at the line so the decision is instant. Reporting and planning can run in your cloud or your data centre.

Will it replace our quality and maintenance teams?

No. It tells them where to look first. The decisions and the sign-off stay with your people.

TALK TO AN AI EXPERT

Tell us what's slowing your team down.

A couple of sentences is enough. One of the senior team reads every enquiry and replies with how we would approach it.

Rather talk it through? Book a call with the team

You'll speak to the senior team from the first call.

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