Manufacturing consulting · Applied AI
Build the plant.
Then make it think.
We take manufacturers from bare land to a line that predicts its own failures. Six practices, installed as one system, on your floor, by people who have run plants themselves.
Who we are
We help manufacturers design, build and run plants that the world’s most demanding brands trust, and we stay until your own team can hold the gains.
Featured insights
Perspectives from the shop floor
What we see across plants and sectors, written for owners and plant heads who have to make the call.
The six levers of a world-class footwear plant
Global brands are spreading their sourcing and rewarding suppliers who are fast, right first time and compliant. The plants that win pull six levers together.
Read the perspective
Design the intelligence in before the concrete is poured
It is far cheaper to place sensors, data cabling and material flow on a drawing than to retrofit them into a running plant.
From registers to real time: what AI actually changes on the floor
AI earns its place when it changes a decision on the shift, not when it adds another screen to the office.
Energy is the one meter every practice reads
The same meter data that feeds an OEE model also feeds carbon accounting. Measure once and use it twice.
Capabilities
Six practices. One operating system.
Most plants buy these from five vendors and spend years making them talk to each other. We install them as one system, because the data, the standard work and the people are the same in all six.
Greenfield plants
From bare land to a running line, with flow, people and data designed in before the concrete is poured.
0 → 1land to first article
Operations & lean
Value stream mapping, line balancing and standard work that turn days of waiting into hours of flow.
+18%throughput in 11 weeks
People & HRMS
Organisation design, hiring, skills and pay that make a new standard the way the shift actually works.
1record for every operator
Quality, chemistry & ESG
Quality built in at source, chemistry held inside its window, and compliance that survives any audit.
3scopes, measured not estimated
Maintenance & reliability
Total productive maintenance that makes the machine available because the operator owns it.
85%world-class OEE, held
AI & digital
Bluro AI, our own manufacturing ERP, with models that run on the line rather than in a pilot deck.
11 wkpilot to production
Client result · Installation 01
A multi-plant components manufacturer
Four plants in three countries sharing vendors. Eleven weeks on the line, with a target agreed in week two. Two cycles after we left, all three measures were still moving in the right direction.
Industry spotlight · Footwear
From hide to box, every step has a standard
Footwear is where our practice began. We know the cutting room, the closing line, the lasting floor and the chemistry room, and the buyers they ship to.
Our technology · Bluro AI
Our own AI-powered ERP, built for the shop floor
Bluro AI links every order from booking to dispatch: costing, materials, planning, shop-floor tracking, quality, maintenance and people, on one data core.
- Delivery-date prediction at order entry
- Line scheduling by capacity, skills and materials
- Defect detection from a phone photo
- Ask your plant a question in plain language
How we work
The person who scopes the work does the work
There is no layer of analysts between you and someone who has done this before. That limits how much work we take on, and we will tell you when we are full.
Weeks 1–2
Two weeks on your floor
We walk the line, read the data you already have and talk to the shift. You get the constraint, what it costs and a priced plan.
Week 3
A number before a contract
Scope, price and the measure we will be judged on, in writing. The diagnostic is yours whether or not you engage us.
Handover
We leave, and it holds
Standard work written with your operators, your people certified, and a handover against the agreed exit number.
Beyond the plant · MADE HERE
A child in Tamil Nadu can finish school without ever meeting an engineer
MADE HERE is our schools programme: six modules on how a factory actually works, taught by practitioners and funded by manufacturers, in the schools around their plants.
