Machines & PLCs
A gateway on your site reads machine states, counts and alarms over OPC UA or MQTT and sends them over a signed, encrypted connection. Read-only: nothing is ever written back to your PLCs.
Connect production, quality, maintenance and material data to identify losses, prioritize action, and measure operational ROI.
Production information is often scattered across machines, ERP systems, spreadsheets, quality records, maintenance systems and operator reports. Synergy Axella brings these operational signals together so your teams can identify where performance is being lost and where improvement will have the greatest impact.
Every minute of downtime reduces available capacity, increases production cost and puts delivery commitments at risk. Identify downtime, speed losses and changeover inefficiencies to recover lost production capacity.
Returns automaticallyScrap, defects and rework consume valuable materials, labor and production capacity while increasing the cost of poor quality. Identify recurring quality losses and their root causes to improve yield and reduce waste.
Returns automaticallyUnplanned equipment failures disrupt production, reduce asset availability and force teams into costly reactive maintenance. Identify recurring failures and downtime patterns to improve equipment reliability and uptime.
Returns automaticallyMaterial shortages, excess inventory and warehouse delays can stop production, tie up working capital and disrupt customer deliveries. Improve material visibility and flow to keep production supplied and reduce unnecessary inventory.
Returns automaticallyEnter rough numbers for one plant. The estimate updates instantly, no email needed.
Indicative estimate only. Assumes 48 production weeks per year and that 20-35% of the identified losses can be recovered in a first improvement cycle. Material stoppages use your downtime cost per hour. Real figures are confirmed during the pilot.
Fourteen integrated modules covering every aspect of plant operations, from real-time production tracking to executive decision-making. Fully localized in 9 languages: English, Spanish, Dutch, French, Italian, German, Portuguese, Polish & Russian.
Live production monitoring with OEE, availability, performance and quality broken down by line, shift and product. Real-time dashboards, hourly targets vs actuals, cycle-time distribution and Pareto of the top losses. Replaces manual whiteboards and Excel trackers so supervisors see reality on-shift, not the morning after.
Operators log stops in seconds from tablet or shopfloor terminal, with reason-tree, sub-reason and photo evidence. The AI Loss Investigator groups repeat events, correlates them with product, shift and operator, and quantifies annual financial impact so you attack the losses that actually move the needle.
Non-conformance capture, 8D/5-Why root-cause diagrams, containment actions, and CAPA workflow with owner, due date and sign-off. Live SPC charts (X-bar R, p-chart, c-chart) flag drift before it becomes scrap, and every closed CAPA feeds back into your knowledge base.
Preventive maintenance scheduling with calendar and runtime triggers, work-order dispatch, spare-parts consumption and MTBF/MTTR tracking. A predictive ML layer flags anomalies from PLC telemetry so you catch bearings, motors and valves before they take a line down.
QR / barcode scan-in and scan-out on mobile, FIFO enforcement, lot and serial traceability, and live stock across raw, WIP and finished goods. Cycle-count workflows, low-stock alerts and integration hooks to your ERP so material never stops the line and never spoils in the racks.
Real-time WebSocket board that broadcasts stoppages, quality holds and safety events to plant-floor kiosks, supervisor phones, Slack and MS Teams simultaneously. Escalation ladders (60s, 3min, 15min) route unresolved alerts up the chain so nothing gets buried.
Ask plain-language questions across all your operational data using Claude Sonnet 4.6, GPT 5.6 or Gemini 3.1 Pro. Generate weekly narratives, spot correlations across downtime, quality and shift, draft improvement plans, and translate SOPs into any of 10 supported languages.
Executive digest delivered every Monday morning across email and dashboard, showing OEE, downtime cost, quality PPM, safety incidents, top 3 wins and top 3 concerns per plant. Daily AI briefing summarises overnight events so leaders start the day already caught up.
Fast incident and near-miss capture with photo, location tag and severity, plus safety walk checklists, JHA/JSA templates, corrective-action tracking and OSHA / ISO 45001 reporting. Culture-of-safety metrics (near-miss rate, days since incident, participation) visible plant-wide.
Kaizen boards, PDCA cycles, A3 problem-solving templates and idea capture that gives every operator a voice. Impact tracking ties each closed kaizen to hours saved, scrap reduced or capacity recovered, making improvement visible and rewarded.
Skill matrix showing who can run which line at which skill level, digital SOP library with photo and video steps, versioning and read-and-sign compliance. Onboarding paths for new hires cut ramp-up time in half and quality escapes from untrained operators drop to near zero.
Native Slack and MS Teams integration pushes plant alerts, shift summaries and CAPA updates into the channels your teams already live in. Two-way commands let supervisors close alerts, acknowledge escalations and query KPIs without leaving chat.
Live plant model driven by PLC and OPC-UA data, showing throughput, WIP and bottlenecks in real time. Run what-if scenarios (extra shift, changeover reduction, new SKU) against the twin before touching production, so you commit to changes with confidence.
Cross-plant benchmarking, financial impact modelling, KPI drill-through from board level to operator screen, and AI-generated narrative that turns numbers into a story leadership can act on. The single pane every plant manager, ops director and COO asks for by name.
Explore the full 14-module platform at app.synergyaxella.com
A 45-second window into the live Platform, real OEE dashboards, downtime AI, kaizens, and executive view in motion.
Thirty seconds of truth. Zero screenshots. Zero mockups.
Illustrative scenarios based on typical manufacturing improvement projects. They are not client case studies. Documented pilot results will be published here once signed off.
Challenge: Production bottlenecks and inconsistent OEE across 3 assembly lines causing 18% capacity loss and missed delivery windows.
Solution: Implemented real-time OEE monitoring, SMED methodology for changeover reduction, predictive maintenance integration, and operator performance analytics with AI-driven insights.
Results:
• 34% OEE improvement (62% → 96%)
• 52% reduction in changeover time
• 28% increase in throughput
• €2.4M annual cost savings
• 99.2% on-time delivery rate
Challenge: Quality deviations causing 12% batch rejection rate, regulatory compliance gaps, and manual documentation errors affecting FDA audit readiness.
Solution: Deployed integrated quality management system with real-time SPC monitoring, automated CAPA workflows, electronic batch records, and AI-powered anomaly detection for early deviation detection.
Results:
• 89% reduction in quality deviations
• Batch rejection rate 12% → 1.8%
• 100% FDA audit compliance
• 67% faster CAPA closure time
• €3.8M annual quality cost reduction
Challenge: Warehouse inefficiencies causing 23% picking errors, inventory accuracy at 87%, and 34% excess inventory tying up €12M in working capital.
Solution: Implemented IoT-enabled warehouse management with real-time inventory tracking, AI-powered demand forecasting, automated replenishment, and optimized picking routes using machine learning algorithms.
Results:
• Picking accuracy 77% → 99.7%
• Inventory accuracy 87% → 99.4%
• 41% reduction in excess inventory
• €4.9M working capital freed
• 56% faster order fulfillment
Low-risk entry into a measurable engagement.
Start with one production line, one department, or one measurable operational challenge.
Identify existing losses and establish performance measurements.
Configure the agreed monitoring and improvement workflow.
Track results, investigate losses, and evaluate corrective actions.
Compare outcomes against the baseline and determine the next phase.
Suggested pilot duration: 30-90 days, depending on scope and data readiness.
A fixed-scope pilot on one line or area, with consulting and the platform included. Choose the pilot length that fits your goal.
Find out where your capacity is going.
Plants new to digital loss tracking, or one critical line.
1 line or work cell, 1 shift pattern
Fix the top losses and prove the gain.
Plants that know their problem and want a measured improvement.
2 to 3 lines or one area, all shifts
Lock in the results and plan the rollout.
Multi-line plants or groups planning to roll out across sites.
A full area or plant, all shifts, 3 or more modules
Every pilot is quoted for your plant. Nothing is committed until you approve the scope. Pricing and delivery commitments are confirmed with you before the pilot starts.
Synergy Axella combines manufacturing expertise, digital operations, and AI to help manufacturers identify operational losses, connect the right people, and turn problems into measurable improvements.
Every engagement starts on the floor, not in a spreadsheet. Synergy Axella baselines your current performance line by line, exposing the micro-stops, bottlenecks and quality escapes that quietly tax your output, so every problem gets a name, a place and a cost.
Returns automaticallyOnce the data is compiled, patterns surface. We bring your teams around a single source of truth to dissect the findings, rank losses by impact and trace each symptom back to its root cause, turning raw signals into a clear, shared picture of where performance leaks.
Returns automaticallyThis is where the platform enters the room. Synergy Axella plugs into the systems you already run, machines, ERP, quality and maintenance records, and converts decisions into motion: live dashboards, instant alerts and guided workflows that put the right people on the right problem, today.
Returns automaticallyGo-live is not the finish line. The platform holds every gain you make, while its AI keeps learning from each shift, tuning schedules, maintenance and quality cycle after cycle, so performance doesn't just recover, it compounds.
Returns automaticallyStart with what you have today. Connect machines and systems step by step, without replacing your MES or ERP.
A gateway on your site reads machine states, counts and alarms over OPC UA or MQTT and sends them over a signed, encrypted connection. Read-only: nothing is ever written back to your PLCs.
Production orders and material movements arrive through your existing middleware into a secure data intake. Every message is signed and checked, so only trusted systems can send data.
No IT project needed to start. Import existing spreadsheets and let operators log downtime, scrap and checks on a tablet at the line, in their own language.
Andon calls, escalations and daily summaries reach the right people where they already work, with an on-call roster so no alert is missed.
Most pilots start with tablet entry and one machine connection, then add more sources once the value is proven.
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Improve productivity, eliminate waste, stabilize processes, and increase operational performance. We help manufacturers build a culture of continuous improvement where every team member contributes to eliminating non-value-added activities and optimizing workflow efficiency.
Identify and eliminate the losses affecting production capacity, OEE, quality, and reliability. We work directly on the shop floor to uncover hidden inefficiencies, optimize machine utilization, and establish sustainable performance baselines that drive measurable results.
Connect manufacturing data, systems, and people into one operational environment. We bridge the gap between shop floor operations and enterprise systems, creating a unified digital thread that enables real-time visibility and data-driven decision making across your entire operation.
Turn manufacturing data and knowledge into faster, smarter decisions. We deploy AI-powered tools that learn from your operational data to predict failures, optimize schedules, detect quality issues early, and capture institutional knowledge, transforming your manufacturing intelligence into a competitive advantage.
Benchmark your plant against your industry across the four pillars of Operations Excellence. Instant personalized report. No sales call required.
Start the free plant assessment →From highly regulated aerospace and medical environments to high-volume automotive, advanced electronics, and complex industrial operations, Synergy Axella helps organizations improve performance across the entire operational value chain.
We help aerospace and defense manufacturers improve production performance, quality, traceability, and process reliability.
We help automotive and mobility manufacturers improve throughput, production flow, quality, automation, and cost performance across increasingly complex operations.
We help life sciences and pharmaceutical manufacturers strengthen process control, quality, traceability, compliance, and operational performance.
We help medical device manufacturers optimize production quality, regulatory compliance, traceability, and operational efficiency in highly controlled environments.
We help advanced manufacturers improve yield, process stability, production efficiency, automation, and real-time visibility across highly technical manufacturing environments.
We optimize manufacturing processes to improve productivity, quality, material flow, and operational efficiency across high-volume consumer production environments.
We help industrial manufacturers and fabricators improve workflow, capacity, quality, production planning, and resource utilization across complex manufacturing environments.
We optimize the flow of materials and information across receiving, warehousing, production, inventory, and distribution to create more responsive and efficient operations.
For more than 15 years, I have built my career where leadership, manufacturing, technology, and continuous improvement meet. From automotive and aerospace production to carbon-removal technology, steel construction, quality management, and independent consulting, I have consistently focused on one objective, helping people and operations perform at their highest level.
My leadership philosophy was shaped long before I entered manufacturing. During 15 years of service in the U.S. Army, I learned that strong leadership requires discipline, accountability, adaptability, and, above all, a genuine commitment to developing people. Those principles have remained at the center of every team and operation I have led.
Throughout my manufacturing career, I have managed multicultural and cross-functional teams of more than 40 to 150 people in demanding, high-volume environments. At Tesla, Spirit AeroSystems, Climeworks, SMS group, and other manufacturing organizations, I have worked directly with production, engineering, quality, maintenance, procurement, HSE, and supply-chain teams to solve complex operational challenges.
My experience includes leading the daily processing of more than 150,000 aerospace components, achieving 99.8% first-pass yield, improving throughput by 15%, reducing cycle times by up to 20%, delivering more than $250,000 in annual savings, and helping consulting clients reduce waste by 25,40%. I have learned that meaningful improvement does not come from reports alone. It comes from understanding what is really happening on the shop floor, listening to the people closest to the process, and converting reliable data into focused action.
That belief led me to become the Founder and CEO of Synergy Axella.
Synergy Axella was created to bridge the gap between operational strategy and execution. We combine hands-on manufacturing consulting with an Operations Excellence Platform that helps organizations identify problems with production, quality, maintenance, material losses and many other departments, understand their root causes, and turn operational data into measurable improvement.
My mission is simple, help manufacturers eliminate hidden losses, strengthen their teams, accelerate improvement, and build operations that are more efficient, resilient, and competitive.
Because we connect manufacturing expertise, technology, AI, and execution to help turn operational problems into measurable improvements.
Most tools focus on a specific manufacturing function. Synergy Axella focuses on connecting the journey from operational problem to improvement.
No. Synergy Axella can be positioned as an operational intelligence and improvement layer that complements existing manufacturing systems rather than automatically replacing them.
By helping manufacturers identify losses, prioritize opportunities, take action, and continuously measure the operational impact of improvement initiatives.
We do not publish standard pricing because every plant engagement is scoped to your production lines, sites, languages, system integrations and the level of consulting required. Most clients start with a fixed-scope paid pilot of 30, 60 or 90 days on one line, department or operational challenge. Each pilot is quoted per plant after a short scoping call, and pricing and delivery commitments are confirmed before the pilot starts. After the pilot, costs scale with your rollout, from a single-plant deployment to a multi-plant network. Historically, clients see a first-year return that is a strong multiple of their initial investment, with results clearly measurable via the executive dashboard.
OEE (Overall Equipment Effectiveness) measures the percentage of planned production time that is truly productive. It combines three factors: Availability (uptime), Performance (speed vs ideal) and Quality (first-pass yield). We improve OEE by instrumenting every line against the 6 big losses, running a cadence of SMED for changeovers, TPM for maintenance and short interval control for shift management. Typical result: 8-15 OEE points inside the first 90 days per line.
Three key differences. First, we combine hands-on manufacturing consulting with the platform, no other vendor in this space does both. Second, we ship in nine languages (English, Spanish, German, French, Italian, Dutch, Portuguese, Polish, Russian) across the full application, not just the UI. Third, the AI Copilot is multi-model (Claude, GPT, Gemini) through one interface, with every prompt grounded in the plant's own data at query time. Tulip is strong on low-code operator apps but has no consulting arm. Sight Machine is strong on analytics but lacks NCR/CAPA, Maintenance and Training. SAP MII is strong on ERP integration but weak on operator UX and typically 12-24 months to roll out.
ERPs: SAP (S/4HANA, ECC via MII and native connectors), Oracle (JDE, EBS, Fusion), Microsoft Dynamics 365, Infor (CSI, M3), IFS, Odoo. Each integration ships as a reusable connector; typical setup is 2-6 weeks per integration. MES co-existence: Siemens Opcenter, Rockwell FactoryTalk ProductionCentre, SAP MII, Werum PAS-X (pharma), GE Proficy, Aptean. We rarely replace an in-place MES, we complement it with the modules the MES is weak at (Continuous Improvement, Training, AI, cross-plant executive view).
Yes. Operator tablets and mobile UIs cache locally for up to 24 hours and sync when connectivity returns. The most-used offline flows are shift handovers, downtime entries, 5S checklists and quality checks. The AI Copilot runs only when connected, but every form submission, SOP read-and-sign and Kaizen-event entry works offline.
Yes. We offer a signed Data Processing Agreement, publish a full sub-processor list, host in EU regions by default (US and APAC regions available on request), build right-to-erasure workflows into the user admin, and run strictly-necessary cookies only on the marketing site, no tracking, no third-party advertising. All legal documents are published at https://www.synergyaxella.com/legal/en/privacy.html
Every Copilot query is enriched at runtime with context from the plant: the specific line, asset, product, operator, shift and recent history. For example, when invoked on a downtime log entry, the Copilot already knows which asset is down, when it was last serviced, what the top 3 root causes were in the last 90 days on this asset, and which operators have expertise with it. This is not generic ChatGPT, it is a grounded manufacturing agent.
Pilot plants are typically live inside 2-4 weeks. We prefer to start with one line, instrument downtime + production + a single quality workflow, prove 5-8 OEE points of improvement, then scale to the full plant and across the network. Discovery takes 1 week, configuration 1-2 weeks, operator training 1 week, go-live on week 3 or 4.
The Loss Investigator is an AI-powered deep-dive on any production, quality, maintenance or material loss. It reconstructs the timeline from your platform data, hypothesizes root causes using the asset's history and similar past events across your network, scores evidence quality, and suggests countermeasures with expected impact. Every investigation is stored as a 'loss_investigations' record with full chain of custody, auditable, exportable to PDF, and attachable to a CAPA.
By default, data is hosted in EU regions (Frankfurt). US and APAC regions are available on request. Access is limited to the authorized users you define, Synergy Axella employees do not access customer data except in explicitly authorized support cases, logged with timestamp and reason. The full sub-processor list (hosting, email, SMS, LLM providers) is published at https://www.synergyaxella.com/legal/en/subprocessors.html
Yes, visit https://www.synergyaxella.com/assessment to take the free 10-minute diagnostic. In 5 steps you will get an instant personalized report scored across the four pillars of Operations Excellence (OpEx, Manufacturing Performance, Digital Manufacturing, AI & Intelligent Ops), benchmarked against your industry median and with an estimated annual recoverable value. Available in all 9 languages. No sales call required unless you want one.
Tell us about your plant and we'll come back within 24 business hours with an assessment scope, timeline and a 15-minute intro call.