Run leaner.
Run smarter.
See exactly where productivity, energy, and assets are leaking value across your operations — and act on it before it hits your P&L.
The intelligence layer your operations have been missing
AI Operations Assistant sits on top of your existing systems and continuously evaluates productivity, energy use, and asset performance — turning fragmented operational data into clear actions that lift efficiency and protect uptime.
Boost productivity
Spot where hours are being spent versus what’s actually getting done. Identify bottlenecks, rebalance shifts, and unlock capacity you already have.
Cut waste
Track consumables, inventory, and energy against actual output. Surface shrinkage, over-ordering, and avoidable cost — before it hits month-end.
Predict failures
The platform watches performance trends across your assets and flags equipment heading for breakdown — turning emergency repairs into scheduled maintenance.
Built around four sources of operational waste
Each capability targets a specific place your operations are losing money — and replaces guesswork with live, defensible numbers.
See exactly where hours turn into output — and where they don’t
Theta compares hours logged against work actually delivered, broken down by shift, line, and team. Bottlenecks show up immediately, not at quarterly review.
- FTE productivity tracking by shift, role, and area
- Bottleneck detection across teams and equipment
- Real-time labor cost-per-output calculations
- Smart shift scheduling based on demand patterns
Stop the silent cost leakage on materials
Match what was ordered against what was actually used. Surface shrinkage, over-ordering, and waste patterns — automatically, across every category.
- Ordered-vs-used reconciliation in real time
- Shrinkage and waste pattern detection
- Reorder-point intelligence by usage trend
- Category-level cost variance reporting
Link every kilowatt-hour to actual output
Energy is one of your biggest variable costs — and one of the least visible. Theta connects consumption to productivity, showing where you’re burning power without producing value.
- Live energy consumption per line, asset, and shift
- Energy-cost-per-unit-produced metric
- Idle-load detection (energy used while not producing)
- Peak demand forecasting to reduce tariff exposure
Catch equipment failures before they catch you
Theta watches performance trends across your assets — vibration, temperature, throughput drift — and flags equipment moving toward failure. Schedule the repair, don’t react to the breakdown.
- Continuous asset health scoring
- Failure prediction from performance trends and sensor data
- Maintenance scheduling optimized around production windows
- Total cost of ownership tracking per asset
From operational signals to bottom-line impact
Four steps run continuously on every shift, every line, every asset — automatically, around the clock.
Monitor
Connect to your existing systems — ERP, MES, SCADA, IoT sensors — and pull in operational data continuously.
Analyze
Machine learning identifies patterns, anomalies, and waste across productivity, energy, and asset performance.
Predict
Surface forward-looking alerts: failing equipment, capacity gaps, energy spikes — with time to act.
Optimize
Push specific, prioritized recommendations to operations leaders. Every improvement is tracked to its ROI.
Built for operations-heavy businesses
AI Operations Assistant pays for itself fastest where productivity, energy, and uptime directly drive your unit economics.
Manufacturing
Multi-line plants where throughput, scrap, and machine uptime drive every shift’s contribution margin.
Energy & Utilities
Asset-heavy operations where downtime is measured in tens of thousands per hour and energy is a primary input cost.
Warehousing & Logistics
High-throughput distribution where pick rates, dock turnaround, and equipment availability shape the entire P&L.
Mining & Heavy Industry
Capital-intensive sites where equipment availability and energy consumption define cost-per-tonne economics.
Construction & EPC
Multi-site builds where equipment productivity, fuel use, and crew utilization drive project profitability.
Industrial Services
Field-services and facilities operators where labor productivity and asset reliability shape every contract margin.
Common questions
How quickly can we see operational improvements?
Most teams are live in 4-6 weeks, with the first wave of efficiency insights surfacing within the first month. Predictive maintenance models reach full accuracy after 60-90 days of learning from your operational patterns.
Do we need to replace our existing ERP, MES, or SCADA systems?
No. AI Operations Assistant integrates with the systems you already run — SAP, Oracle, Rockwell, Siemens, GE, AVEVA, and most custom MES platforms — adding the intelligence layer on top.
What data does the platform need to be effective?
Production output, shift records, energy consumption, asset sensor data, and inventory transactions are the core inputs. We work with whatever sources you have — even if some are still in spreadsheets — and progressively connect more over the engagement.
How does it handle multi-site operations?
The platform is designed for portfolio-level visibility from day one. Site-level dashboards roll up into regional and group views, with benchmarking across sites and standardized KPIs for like-for-like comparison.
How accurate is the predictive maintenance?
Accuracy improves as the AI learns your equipment patterns. Most customers see meaningful failure prediction within 60 days. Every alert comes with reasoning — the trend that triggered it and the recommended action — so your engineers stay in control.
Can we start with one site or production line?
Yes. Most engagements start with a focused pilot on one site or line over 60-90 days. Once results are proven, scaling to the rest of the portfolio is fast because the integrations and models are already established.
See where your operations are leaking value
Book a 30-minute demo. We’ll walk through your operational data and show exactly what Theta would surface — productivity gaps, energy waste, and at-risk assets — in real time.