MANUFACTURING AX — MANUFACTURING-FLOOR AI TRANSFORMATION

You have a smart factory —but has it turned into AI results?

Consulting that diagnoses and standardizes your scattered plant data into one manufacturing AI OS, and puts proven manufacturing AI (predictive maintenance, anomaly detection, quality prediction) genuinely to work to deliver results in the short term. The results you earn here become the starting point for the lights-out transformation to a dark factory.

FIELD 200+ SITES / 16 YRS · SOLUTIONS 20 · AI→PLC DIRECT CONTROL VERIFIED · L1 → L3

01PROBLEMSCATTERED DATA — HARD TO FIND · USE · PROTECT

Scattered data is hard to find,
hard to use, hard to protect.

Plant data is scattered across equipment, MES, ERP, spreadsheets and chat — finding it, using it and protecting it all become bottlenecks.

P-01

Hard to tell which data is current

People burn time hunting for the truly latest value across equipment logs, daily production sheets and spreadsheet copies.

P-02

Hard to put data to work in AI

Without standardization and integration, you just repeat PoCs — adopting AI never turns into results.

P-03

Hard to control access

With no clear permissions by role and rank, sensitive information like drawings, cost and quality risks being exposed.

P-04

Hard to know where to start

The need for AI is clear, but it's unclear what to standardize first and what to automate first.

02WHAT IT ISDIAGNOSE · DESIGN · BUILD

Here's what Manufacturing AX Consulting does.

WACE's manufacturing-AI engineers go on-site, examine your company's data structure, diagnose and design what to standardize and integrate so AI can be put to work, and take it through to the build. We centralize scattered data into one manufacturing AI OS and build a system that delivers results on the floor right away. The results earned here extend into system build and AI agents, and whole-plant lights-out continues into Dark Factory Consulting.

Scattered data centralizing into a single core

FIG — SCATTERED → CENTRALIZED

SOL-01

Scattered data onto one standard

We find data managed separately by equipment, department and system, unify it in one place, and standardize and cleanse it so AI can use it right away. The whole company works from the same source, the same standard.

BASESCATTERED → CENTRALIZED · 834+ STANDARD TABLES · 311+ ONTOLOGY RELATIONS

SOL-02

Standardized data into real results

We connect it straight to proven AI use cases. Data made on the floor accumulates as a company asset, and running staff training and one-on-one facilitation alongside speeds up adoption.

USE CASESPREDICTIVE MAINTENANCE · ANOMALY DETECTION · QUALITY PREDICTION · REPORT AUTOMATION

SOL-03

Gathering it isn't the same as securing it

We clean up duplicate and non-standard data and centrally control access by role and rank, so anyone can find the latest data fast and use it safely.

PATH01 DATA INTEGRATION → 02 STANDARDS & PERMISSIONS → COMPANY-WIDE USE

SOL-04 · VERTICAL

A floor signal that reaches the boardroom the same day

There is a familiar way AI adoption loses steam: the shop floor gets automated, and management never feels the difference. So we scope a diagnosis not by how many tasks it covers, but by how many levels of the organization one thread runs through — designing the full chain where a floor signal climbs through the supervisor's daily report and the plant manager's KPIs into the language of that day's management decisions.

THREADFLOOR SIGNAL → SUPERVISOR'S DAILY REPORT → PLANT-MANAGER KPI → MANAGEMENT DECISION

03IN ACTIONREAL PRODUCT SCREENS

After adoption, this is how
the factory works.

Once data governance is in place, this is how the way the factory works changes. Below are real VEXPLOR screens.

D-01 · Manufacturing

Automated predictive maintenance

AI catches early signs of equipment trouble in real time and alerts the right person the moment risk crosses a threshold.

STACK — PREDICTIVE MAINTENANCE LSTM · ANOMALY DETECTION · THRESHOLD ALERTS

D-02 · Manufacturing

Automated root-cause analysis for quality

AI cross-checks process data to flag defect patterns early and presents cause and response with the evidence attached.

STACK — 4-WAY RAG · ONTOLOGY EVIDENCE CHECK

D-03 · Manufacturing

AI → direct equipment control

It syncs digital-twin predictions with the live floor and pushes AI decisions down to the PLC to control equipment directly.

STACK — 3D TWIN · AI→PLC DIRECT CONTROL VERIFIED

D-04 · Manufacturing

Automated floor and production reporting

AI automatically compiles daily and weekly output, utilization and inventory, adds a summary, and sends it at a set time.

STACK — SHOP-FLOOR POP · AUTO-COMPILED REPORTS

COMPANY-WIDE EXPANSION

Beyond production — Work AX Consulting

AI automation of office work like sales, contracts, inquiries and reports is covered by Work AX Consulting. It extends naturally into the non-production departments of Manufacturing AX customers.

LONG-TERM — LIGHTS-OUT

Whole-plant autonomy — Dark Factory

The roadmap from the results earned here to a lights-out plant run by AI is designed by Dark Factory Consulting.

Screen data is shown for illustration — not presented as complete

04NEXT STEPSHORT-TERM PROOF → LONG-TERM TRANSFORMATION

After Manufacturing AX delivers results,
where do you go next.

Manufacturing AX is a broad entry gateway (L1→L3). Once data standards and verified results accumulate here, it expands in two directions on top of them — into whole-plant lights-out operation run by AI (a dark factory), and into office-work automation for the non-production departments.

LONG-TERM · L3 → L4

Dark Factory Consulting

A masterplan that turns the whole plant into unmanned autonomous operation through the staged journey and gates of foundation, integration, intelligence and autonomy. The results of Manufacturing AX are the starting point of that journey.

JOURNEYFOUNDATION → INTEGRATION → INTELLIGENCE → AUTONOMY · WAVE-SEPARATED INVESTMENTSee Dark Factory Consulting →

CROSS · COMPANY-WIDE

Work AX Consulting

AI automation of office work — sales, contracts, inquiries, reports. It runs on top of company-wide data centralization and permission governance by role and rank. It extends into the non-production departments of manufacturing customers.

SCOPEDATA CENTRALIZATION · PERMISSION GOVERNANCE · WORK AUTOMATIONSee Work AX Consulting →

05DIAGNOSIS8-WEEK PROGRAM · WEEKLY REVIEW · ENGINEERS ON-SITE

The 8-week diagnosis — the final report's
contents are agreed in week one.

Every journey starts with a diagnosis. The standard diagnosis-and-design program runs eight weeks, carried out on-site by WACE manufacturing-AI engineers. The timeline adjusts to the state of your plant (and is fixed in the diagnosis), but the skeleton — and the moments where you check in — stay the same.

Kickoff

We align on goals and success criteria, and agree the table of contents of the final report together. From week one, you know what will come out at the end.

EVERY WEEK

A 45-minute weekly review

A fixed day, a fixed format — progress, new findings, issues that need a decision, next week's plan. There is not a single week when you don't know where the project stands.

Interim report

Your current position and the list of broken links blocking autonomy — confirmed together with management.

Individual pre-briefings

We brief each key executive in person beforehand — so nothing in the final report is heard for the first time.

Final report & handover

The final report, together with the execution roadmap and the operating handover.

W1 KICKOFF → WEEKLY 45-MIN REVIEW → W4 INTERIM REPORT → W7 PRE-BRIEFINGS → W8 FINAL REPORT · HANDOVERWHAT YOU RECEIVE — DIAGNOSIS REPORT · INTEGRATION DESIGN · EXECUTION ROADMAP · 1-PAGE EXECUTIVE SUMMARY · OPERATING HANDOVER PACKAGE / STAFFING: 1–3 WACE MANUFACTURING-AI ENGINEERS ON-SITE

06HOW WE WORKQUALITY PROMISE ×4 · PAY AFTER PROOF

How we work — you pay after
you've seen the result.

We work by predictable rules. Four quality promises we keep, and the roles we ask of you to make the project succeed.

Q-01

Every number has a source

Any figure in a report can be traced in a footnote to which data it came from, and how.

Q-02

Diagnostic figures are reproducible

For figures computed from your data — utilization, defect rates — we hand over the calculation as a script. Only when you can reproduce the same value from the same data does a diagnosis become measurement rather than assertion.

Q-03

No surprises

The substance of interim and final reports is shared individually before the meeting. The worse the news, the earlier it arrives — and in writing.

Q-04

Three honest options when a gate is missed

Remediate and re-judge, proceed with only what passed, or stop and settle — agreed with you and put on paper. We do not paper over a miss and move on.

GATE PASSED = STAGE ACCEPTED = INVESTMENT RELEASED — YOU PAY AFTER YOU'VE SEEN THE RESULTSTAGE COMPLETION IS JUDGED JOINTLY AGAINST PRE-AGREED CRITERIA · INVOICING IS TIED TO GATE PASSAGE

YOUR TEAM · R-01

Executive sponsor

One executive to join the monthly steering meeting and approve the stage gates.

R-02

Project owner

One working-level lead to attend the weekly reviews and coordinate internally.

R-03

Data authority

Someone to approve the provision and release of system data.

R-04

Site liaison

Someone to arrange interviews and floor inspections.

Recommended — one or two of your engineers join the project and do the analysis with us. Not observing but sharing the actual work: the surest way the capability stays with you

07STANDARDS12 PLAYBOOKS · 339 CHECKS · CERTIFIED BEFORE STAFFING

The same quality, whoever shows up —
we work from documented standards.

Consulting that rests on individual brilliance changes quality when the consultant changes. We run every activity of the diagnosis from documented standards — whoever is staffed, the same order, the same criteria, the same quality.

ST-01

12 activity playbooks

From pre-diagnosis to closeout and handover, every activity has its procedure written down — down to the standard lines a session opens with.

SCOPEPRE-DIAGNOSIS → KICKOFF → INTERVIEWS → VERDICTS → WEEKLY REVIEW → REPORTING → CLOSEOUT · HANDOVER

ST-02

339 execution checks

Every activity is run against a checklist — and the check record itself is the evidence for stage acceptance.

EVIDENCECHECK RECORD = GATE EVIDENCE

ST-03

Certified before staffing

Every consultant completes training and a pass-required assessment before joining a project, then supervised field work before leading alone.

GATEPASS-REQUIRED ASSESSMENT · SUPERVISED FIELD TRAINING

ST-04

A reproduction script with every figure

Every diagnostic figure ships with the script that computed it. You can re-measure the same value at any time.

REPROSAME DATA → SAME VALUE — ANY TIME

The whole system is updated after every project — your project's experience becomes the next standard

08FIT & ESTIMATE4 PROFILES · 3-AXIS · NO LIST PRICE

It fits companies like these —
and here is how we price it.

T-01

Manufacturing AX transformation

Manufacturers moving beyond the smart factory to a stage where AI runs the plant.

T-02

Manufacturing data governance

Companies looking to unify data scattered across equipment, MES, ERP and spreadsheets.

T-03

Real AI results

Companies that want proven AI to deliver results instead of repeating PoCs.

T-04

First AI adoption

Mid-sized and small manufacturers taking their first AI adoption across the line without a stumble. (For office and company-wide expansion, see Work AX Consulting.)

SCOPE

What's included

Data and floor diagnosis · AI use-case design · build and integration · closeout report.

TEAM1–3 WACE MANUFACTURING-AI ENGINEERS · TIMELINE SCOPED TO YOU

FORMULA

Three pricing axes

Data scale and integration breadth / scope of use-case design (number of AI use cases) / build and integration depth.

3-AXISDATA SCALE · USE CASES · DEPTH

PACKAGE

Bundled discount

We scope an exact quote after a meeting, and bundling consulting with training earns a discount.

OPTIONGROUP-TRAINING BUNDLE DISCOUNT · 1:1 FACILITATION EXTRA DISCOUNT — GROWS AS YOU BUNDLE

Pricing page — see the full basis →

09WHY WACEDOMAIN DEPTH × STANDARDS × PRODUCT

There's a reason it has to be WACE.

W-01

Manufacturing depth, proven

16 years and 200+ manufacturing-site engagements. AI→PLC direct control verified, two government-backed AI autonomous factory builds underway — territory a generalist AX vendor struggles to enter.

PROOF200+ SITES / 16 YRS · AI→PLC VERIFIED · AUTONOMOUS FACTORY ×2 SITES

W-02

Built on national standards and patents

We lead the consortium developing Korea's manufacturing-data standardization reference model (AAS/IEC 63278), hold 1 registered and 2 pending manufacturing-AI patents, and run a corporate R&D lab with ISO 9001.

IPPAT REG 1 + PENDING 2 · IEC 63278 · R&D LAB · ISO 9001

W-03

Product-backed consulting

We consult on top of a Manufacturing AI OS with 20 industrial solutions, 834+ standard tables and a manufacturing-tuned 4-Way RAG, so diagnosis flows straight into build and operation.

BASESOLUTIONS 20 · TABLES 834+ · 4-WAY RAG

CASE-15%Defect rate — Company H (die casting)

CASE99%Inventory accuracy — Company K (automotive electronics)

EXPECTED-90%Data processing time

EXPECTED-15%Process operating cost

And this is consulting whose methodology exists as documents — the 8-week diagnosis (05), the quality promise (06) and the 12 playbooks (07): how we work is open before you sign

Resources — download the consulting brochure →