Recover 23% Production Efficiency Without Replacing Your Equipment
Olyra's AI Operations Consulting is a 4-week AI diagnostic for mid-market manufacturers. We find the hidden capacity in your existing operation — uptime, quality, scheduling, labor, maintenance — and surface the AI interventions that recover the most margin, fastest.
If you run a plant, you're probably losing 15-25% of capacity in five places
Unplanned downtime nobody saw coming
Equipment failures interrupt 5-20% of available capacity. Maintenance is reactive. Predictive vendors promised value and never delivered. The same lines fail in the same ways every quarter.
Quality defects discovered downstream
Defects show up at the QC station, not at the point of cause. By the time you find the root cause, you've scrapped a shift. Process drift is invisible until it's expensive.
Production scheduling done in Excel
The schedule misses real-time constraints — material shortages, changeover penalties, labor availability — and gets re-cut by hand every shift. Throughput suffers.
Maintenance burning OEE
Reactive maintenance crews are heroes, not strategists. There's no clear view of which assets are deteriorating, which interventions return the most uptime, or where to spend next year's CapEx.
Tribal knowledge walking out the door
Your most experienced operators are retiring. The decisions that prevented breakdowns lived in their heads. AI can codify what they know — if you start before they're gone.
MES, SCADA, and ERP that don't talk
Plant-floor data trapped on the floor. ERP data lagging by hours. Quality data sitting in PDFs. The view of the operation is fragmented, late, and incomplete.
average operational efficiency improvement within 120 days
Across logistics, retail, manufacturing, and services clients. For manufacturing specifically, this typically maps to OEE gains of 8-12 points and unplanned downtime reductions of 25-40%. See our results methodology →
How our consulting engagement works in manufacturing
A focused 4-week diagnostic. We start on the floor, not in a conference room.
Assess
Weeks 1-2: We connect to your MES, SCADA, ERP, and quality systems. We walk every line. We profile every asset, every defect class, every unplanned event for the past 12 months.
Illuminate
Week 3: We surface the operational blind spots — quantified in dollars and OEE points, ranked by ROI, and mapped to specific AI or process interventions.
Accelerate
Week 4 + beyond: You receive a prioritized action plan. We can build and deploy the highest-ROI interventions with your team — predictive maintenance models, scheduling optimization, quality early-warning systems.
The Manufacturing OEE Scorecard
A 15-question diagnostic that produces a personalized OEE report grading your plant across the six dimensions where mid-market manufacturers leak the most capacity — with industry benchmarks for your segment and three specific recommendations.
- Score your plant in under 6 minutes
- Industry benchmarks for auto parts, food/bev, industrial equipment, and more
- Three personalized recommendations with estimated OEE impact
- Built for plants, not data scientists
How a 2-plant manufacturer cut unplanned downtime 31% in 90 days
The challenge
A discrete manufacturer was running OEE in the low 60s. Maintenance was reactive. The same five assets accounted for 70% of unplanned downtime, but nobody had connected the failure patterns to early-warning signals already present in vibration and temperature data the SCADA system was capturing — and discarding.
Olyra deployed a 4-week consulting diagnostic. We connected SCADA, CMMS, and ERP data. We built predictive failure models on the five worst-offender assets and a quality early-warning system on the highest-defect line. Implementation began in week 5.
Read the full case study →Measured Outcomes
What plant leaders say about working with Olyra
The consulting diagnostic found 9 OEE points hiding in our existing SCADA data. We didn't buy new equipment — we just used what we had better.
Two predictive maintenance vendors had failed in this plant before. Olyra worked because they started with the operations problem, not the technology.
What I valued most was that they spent week one on the floor, not in our conference room. Senior consultants — not juniors — every visit.
Ana Fernandes
Ana spent 15 years in operations leadership at industrial and supply-chain companies before founding Olyra. She built the firm to bring AI-driven operational intelligence to mid-market manufacturers — companies that need the insight without the Big Four price tag or a 9-month engagement.
Olyra's team operates from Miami and São Paulo, serving manufacturers across North America and Brazil. Every consulting engagement is led by senior consultants with hands-on plant-floor experience.
Connect with Ana on LinkedIn →Common questions
Find the capacity hiding in your plant.
Get the free OEE scorecard. Or skip ahead and book a 15-minute plant-specific strategy call this week.
Questions first? Email sales@olyra.ai or call M-F 9am-6pm ET.