Andonia AI plugs cameras, sensors, and software into any plant. It builds a live digital twin of the whole flow and shows the one constraint that sets your output.
More work is pushed in than the constraint can handle. It just waits.
The problem
Most factory tech improves one machine or one department. Local numbers go up, but the plant does not ship more. A faster machine that is not the bottleneck only builds inventory, and more inventory means longer lead times.
Tools optimize single machines. Nobody asks if that machine is the constraint.
Most plants do not know where their real bottleneck is, or how it moves over time.
Decisions are based on guesses, and each vendor's system is costly to connect.
How it works
Our approach comes from Lean and the Theory of Constraints. We look at the whole system first, then act where it raises throughput.
Low-cost cameras, sensors, and an edge gateway, plus connectors to ERP, MES, and LIMS. No IT project.
AI builds a live digital twin of the whole flow from real events. No manual modeling.
See where work waits, where the bottleneck is now, and when it moves.
Control when work is released, test "what if" changes in the twin, and automate only at the constraint.
The first win
Little's Law links lead time, work in progress, and throughput. Control how much work is on the floor, and lead time drops while output stays the same. That is a fast, low-cost first step before any larger hardware project.
Lead time = WIP ÷ Throughput
Same output. Less waiting. Exactly what the simulation above shows.
First pilot
Our first pilot is with LABB, an ISO/IEC 17025 accredited environmental lab in Blumenau, Brazil. A lab works like a small factory: samples are the product, and turnaround time is the lead time. We are connecting to its systems to track each sample through every step and find the real constraint.
Contact
We are looking for factories in the US and Brazil that want to cut lead time and raise throughput. Let's talk.
contact@andonia.tech