UNIFIED INDUSTRIAL INTELLIGENCE & QUALITY PLATFORM

Digital Factory & Manufacturing Intelligence.

Unify automated AI quality inspection, connected digital work instructions, real-time shop floor telemetry, and AI-powered MES and OEE analytics into a single high-performance manufacturing ecosystem integrated with our Plant Safety AI suite.

Book a Live Demo Explore All Solutions

PLANT-01 · SHOP FLOOR INTELLIGENCE CLUSTER

REAL-TIME TELEMETRY ON

YAFE Manufacturing Intelligence plant deployment

Line OEE Metric 84.6% (+22% vs base)

In-Line Inspection 15,000 / day (99.2%)

Edge Inference < 14ms Latency

SOLUTION 01 · QUALITY AT THE SOURCE

AI Visual Quality Inspection

Automate surface scratch detection, assembly mistake-proofing, porosity identification, dimensional checks, and high-speed OCR at conveyor speeds.

YAFE AI automated visual quality inspection

Move From Manual Spot-Checking to 100% Automated Vision.

Human inspectors suffer from eye fatigue after 20 minutes on high-speed production lines, leading to missed defects and costly warranty recalls. YAFE inspects every single item at millisecond speeds with repeatable mathematical precision.

✓ Conveyor-Speed Inspection: Processes 120+ parts per minute with synchronized strobing and micro-defect anomaly localization.

✓ Deep Learning Defect Detection: Learns golden reference parts and flags subtle variations without rigid manual rule-crafting.

✓ Instant Pneumatic Ejector Rejection: Direct low-latency signals to line PLC diverters to reject defective parts off the belt.

✓ Digital Traceability & SPC Analytics: Stores inspection snapshots and serial numbers for full audit compliance.

01 Defects

Surface Defect Detection

Detects hairline cracks, blowholes, porosity, burrs, flash, scratches, and gouges on machined metal, plastics, and rubber.

02 Assembly

Assembly Verification

Verifies component presence, fastener count, washer placement, clip seating, wire routing, and connector latching.

03 Traceability

OCR & Barcode Reading

Decodes dot-peen engraved serial numbers, laser markings, 2D DataMatrix codes, and expiration batch labels at high speed.

04 Dimensional

Dimensional Tolerancing

Sub-millimeter non-contact measurement of hole diameters, pitch distances, gap clearances, and flushness alignment.

SOLUTION 02 · CONNECTED OPERATIONS

Digital Work Factory & Connected Shop Floor

Connect people, machines, assembly stations, and standard operating procedures into a paperless, synchronized digital production layer.

From Disconnected Operations to One Synchronized Factory.

YAFE creates a connected digital layer across manufacturing operations, replacing binders of static paperwork with dynamic digital work instructions, live station telemetry, and AI mistake-proofing.

✓ Dynamic Digital SOP Guidance: Tailors interactive assembly step guides on operator touchscreens per scanned SKU.

✓ Poka-Yoke Assembly Interlocks: Locks station advance until tool torque limits and step sequence verification pass.

✓ Real-Time Station Telemetry: Under 50ms sync latency across shop floor assembly cells, buffers, and Andon lines.

✓ 100% Paperless Traceability: Immutable digital logs connecting parts, operators, tools, and batch timestamps for audits.

Digital factory connected shop floor operations

01 / SOP

Digital Work Instructions

Replace paper manuals with interactive step-by-step guidance on ruggedized tablets, ensuring zero missed steps on assembly lines.

02 / MONITOR

Shop Floor Monitoring

Gain real-time operational views across production stations, material buffers, assembly lines, and changeover processes.

03 / BOTTLENECK

Cycle Time Intelligence

Identify line starvation, micro-stoppages, operator pacing differences, and station bottlenecks before they cause downtime.

04 / OUTPUT

Production Throughput

Track real-time shift completion against master production schedules, alerting supervisors automatically to schedule drift.

05 / AUDIT

Digital Traceability

Connect serialized parts, torque values, operator badges, and automated inspection photos into a full digital birth certificate.

06 / CONNECT

Enterprise ERP & PLC Integration

Bidirectional connectors for SAP, Oracle, Siemens PLCs, OPC-UA, MQTT, and SCADA architectures.

SOLUTION 03 · CLOSED-LOOP FACTORY INTELLIGENCE

Manufacturing Intelligence & Real-Time OEE

Bridge the gap between edge vision sensors, machine PLCs, operators, and enterprise MES to optimize plant throughput and yield.

LIVE CV ENGINE · SHOP FLOOR SYSTEM 01

MODULE 01

Inline Quality Inspection

Inspect manufactured components at production line speeds. YAFE detects microscopic surface scratches, missing fasteners, dimensional tolerances, and validates serialized characters with 99.2% mathematical precision.

✓ 120+ parts inspected per minute at conveyor speed

✓ Micro-defect anomaly localization with sub-millimetre resolution

✓ Instant pneumatic diverter trigger for zero escaped defects

CLOSED LOOP ARCHITECTURE

From Physical Factory Signals to Automated Action

Factory Layer

Cameras, machine PLCs, torque tools, digital calipers, and floor operators.

AI Edge Compute

On-premise GPU inference processing feeds in real-time under 15 milliseconds.

Detection Engine

Flags micro-defects, sequence skips, missing parts, and safety perimeter breaches.

Intelligence Hub

Real-time OEE metrics, shift takt-time variance, and serialized traceability records.

Automated Action

Sub-15ms diverter triggers, PLC line stops, digital Andon alerts, and ERP sync.

ENTERPRISE VALIDATION

Proven on Real Production Lines

YAFE manufacturing solutions are actively running in high-volume tier-1 automotive, tyre, heavy equipment, and precision engineering plants.

Apollo Tyres · Quality AI

DOT Code Inspection

15,000 / DAY

Inline AI optical inspection for real-time character validation across high-speed tyre manufacturing lines.

Mahindra & Mahindra · MES

Production Intelligence

62% → 84% OEE

MES digitization improved plant OEE by 22% while assembly rework was slashed by 34% across lines.

Bradken Foundry · Safety AI

Forklift Safety AI

ZERO FALSE

AI vision detects workers entering moving vehicle zones with reliable sub-15ms proximity alert triggers.

JCB Heavy Equipment · Safety

Hazard Zone Interlock

INSTANT TRIP

Continuous monitoring of dangerous robotic welding cells with immediate emergency stop cut-offs.

DEPLOYMENT ROADMAP

From Initial Assessment to Full Production in 60 Days

Our automation engineering team works directly with your plant staff to ensure rapid commissioning with zero disruption to existing line production.

01 / ASSESS

Map Plant & Objectives

Audit current production lines, lighting conditions, camera coverage, and identify high-value defect or throughput bottlenecks.

02 / ARCHITECT

Hardware & AI Calibration

Specify industrial edge compute units, optical lensing, and train custom deep learning neural networks on golden reference samples. Learn more about our edge video architecture.

03 / INTEGRATE

PLC & MES Commissioning

Connect digital I/O relays for diverters and interlocks, integrate ERP/SCADA databases, and configure operator tablets with digital work instructions.

04 / OPTIMIZE

Continuous Scale

Monitor real-time precision metrics, fine-tune model thresholds, and scale validated workflows horizontally across sister plants.