for Industrial Production
Aunifiedintelligenceplatformthatconnectsdisconnectedfactorysystems,deliversreal-timevisibility,andusesAI-poweredschedulingtorecoverlostcapacity—withoutbuyingnewequipment.Builtend-to-endbyFrostrek.
Whatis Manufacturing AI OS?
ManufacturingAIOSisaproduction-readyintelligencelayerbuiltforindustrialmanufacturers.ItconnectsexistingERP,WMS,PLC,andSCADAsystemsintoasinglereal-timedashboard—nohardwarechanges,nosystemreplacements,read-onlyaccess.
Inarecentdeployment,itrecovered20–42tonsofweeklyproductioncapacitybysolvingproductsequencingandvisibilitygapsthatnomachineupgradecouldfix.
The Problem We Solved
Threecriticalgapsholdingthefactorybackfromfullcapacity.
20 Changeovers a Week, Zero Intelligence
The manufacturing plant lost 20–42 tons of weekly production from product changeovers decided by Excel sheets and gut feel — no one was sequencing products intelligently to minimise downtime.
Four Systems, Zero Integration
Syspro ERP, Fusion WMS, CFAM extruder PLC, and Famsun plant system operated as isolated islands — shift handovers happened on WhatsApp, quality readings on WhatsApp, cost per kg calculated monthly from financials when it was too late to act.
Invisible Factory
Management couldn't see the factory floor in real time — no live production data, no changeover tracking, no sensor alerts, no shift accountability beyond verbal reports.
What We Built
Acompletemanufacturingintelligenceplatformengineeredfromthegroundup.
Four-System Integration Layer
Connected Syspro ERP (SQL), Fusion WMS (REST API), CFAM TX80 Extruder (PLC via EtherNet/IP), and Famsun Plant (MQTT) — all read-only, zero changes to existing systems.
Real-Time Factory Dashboard
Live extruder parameters every 30 seconds via WebSocket, orders and job cards synced every 10 minutes, plant equipment status in real-time — one unified view replacing WhatsApp chaos.
Digital Shift Handover & Quality Forms
Replaced WhatsApp shift reporting with structured forms capturing changeover data, quality readings, output, and machine issues — feeding analytics and AI scheduling.
Sensor Alerting System
Configurable thresholds per product; instant push alerts (dashboard, email, WhatsApp via Twilio) when moisture, temperature, or any reading drifts outside acceptable range.
The Impact
75%to85%+capacityutilization—withoutbuyingasinglenewmachine.
Recovered
Lost production from poor changeover sequencing eliminated through AI-optimised scheduling.
Capacity
Factory throughput increased 10+ percentage points with smarter sequencing and real-time visibility.
Investment
All gains from software intelligence — no new extruders, no new PLCs, just better decisions.
Tech Stack
Want manufacturing intelligence
built for your factory?
Let'stalkabouthowFrostrekcanunlockcapacityinyouroperations.