Who We Help AI Services Case Study
Digital products for industry

Operations tools,
finally working
for your team.

Your operations are running — but you can't see what's really going on. It's hard to diagnose why performance drops, hard to get full visibility into cost drivers, and hard to know where the next improvement should come from. We go beyond dashboards — we build AI-driven process intelligence, optimisation models that reduce waste and downtime, and simulations that let you test decisions before committing. From the plant floor through distribution to in-country market logistics. Delivered in weeks, not months.

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OpenAI Select Partner
Based
Singapore · Asia-Pacific
Typical delivery
3–5 weeks per project
Focus
Operations & decision-making tools
Manufacturing plant floor
Plant floor · APAC LIVE OPS
OEE · Line 03 · Today
72.4%
Target 78% +4.2 vs wk
What usually brings people to us
Costs you can't explain
Delays you didn't see coming
Planning nobody trusts
Tools nobody uses
Who we help

Built for operations teams who have to decide now.

Wherever the data is trapped, the tool goes unused, or the call still gets made on gut feel. Most of our work so far has been in manufacturing and supply chain, so that is where the examples below come from — but the pattern travels.

Industrial robotic arm on production line
Plant Operations · Continuous improvement
01

OEE & Production Intelligence

Your OEE reports take days to compile and are outdated by the time they reach your production meeting. We build real-time dashboards that go beyond monitoring — identifying bad actors, surfacing root causes, and recommending continuous-improvement actions so your team knows exactly where to focus.

Pain
"We know our OEE is 78% but we don't know which losses to attack first or what's driving them."
Solve
Automated loss analysis that pinpoints bad actors and prioritises CI actions by impact.
02

Energy & Utilities Analytics

Energy is often the largest controllable cost in manufacturing. We connect your meters to dashboards that show consumption by line, product, and shift — making waste visible and actionable.

Pain
"We know our dryer uses too much energy, but we can't pinpoint when or why."
Solve
Energy per unit of production, benchmarked across shifts and conditions.
03

Yield & Quality Root Cause

When yield drops or quality deviations spike, your team chases the problem manually for weeks. We build analytics that correlate process data with quality outcomes to find root causes in days.

Pain
"We've been investigating this yield issue for 3 months and still don't know the cause."
Solve
Data-driven root cause analysis in 3 weeks, not 3 months.
04

Schedule Optimisation & Changeover

Your production schedule is built manually and changeovers eat into productive time. We build optimisation models that sequence runs to minimise changeover downtime, balance load, and maximise throughput.

Pain
"Our planner spends 2 days a week building the schedule in Excel and we still get too many changeovers."
Solve
Optimised scheduling that cuts changeover time and frees up capacity you didn't know you had.
05

Production Simulation

Before investing in a new line or changing your scheduling logic, test it virtually. We build discrete-event simulation models that let you run scenarios without risking production.

Pain
"We think adding a shift will solve our capacity problem, but we're not sure."
Solve
Simulate 50 scenarios virtually before committing to one change.
Warehouse with stacked pallets
Distribution centre · APAC affiliate
01

Inventory Coverage & Days-on-Hand

Your planners track DOH in spreadsheets that take half a day to update. We build live coverage dashboards that flag risk items automatically — too much, too little, approaching shelf-life expiry.

Pain
"I found out we had 6 months of stock at the warehouse only when it was about to expire."
Solve
Automated shelf-life monitoring with proactive alerts, not reactive discovery.
02

Shelf-Life Management

Nutrition and pharma products have strict shelf-life requirements. We build tools that track remaining shelf life across your inventory, flag at-risk stock, and feed into demand planning.

Pain
"We wrote off $200K of inventory last quarter because nobody caught the shelf-life issue in time."
Solve
Early warning system that catches shelf-life risk 60 days before write-off.
03

DOH Root Cause Analysis

When days-on-hand spike, the question is always "why?" — demand drop, production overrun, forecast error, supplier issue. We build analytics that decompose DOH changes into actionable root causes.

Pain
"DOH went from 45 to 78 days and my team spent 2 weeks figuring out why."
Solve
Automated DOH decomposition — root cause in minutes, not weeks.
04

Supply Chain Network Simulation

Discrete-event simulation of your supply chain — from suppliers through production to distribution. Test demand shifts, supplier disruptions, or capacity changes before they happen.

Pain
"We don't know if our network can handle a 20% demand increase without adding warehouse space."
Solve
Simulate the scenario in 3 weeks and give you a data-backed answer.
05

Market & Affiliate Logistics

Your in-country distribution data is fragmented across markets. We build visibility tools that connect plant output to market demand, track in-country inventory, and monitor service levels — from factory gate to customer shelf.

Pain
"We have no visibility into affiliate inventory once product leaves our warehouse."
Solve
End-to-end visibility from plant to market — inventory, transit, service levels across affiliates.
06

Distribution & Logistics Optimisation

Shipping frequency, route consolidation, warehouse allocation — your logistics decisions are often based on habit rather than data. We analyse distribution patterns and build optimisation models.

Pain
"We ship to the same affiliates on the same schedule every week regardless of demand."
Solve
Data-driven distribution planning that matches logistics spend to actual market needs.
Shipping port with containers
Inbound supply · Port of Singapore
01

MRP Recommendation Analysis

Your procurement officers override MRP recommendations 60% of the time. Is the system wrong, or are the parameters misconfigured? We analyse MRP outputs vs actual purchasing decisions to find out — and fix it.

Pain
"The system keeps telling us to order 500 units but everyone knows we need 2,000. Nobody trusts MRP."
Solve
MRP parameter health check — identify which parameters are wrong and what to set them to.
02

PO Consolidation & Lot Sizing

Different officers handle the same supplier differently — some combine POs, some don't. Lot sizes are inconsistent. We build decision-support tools that standardise purchasing logic and optimise lot sizes.

Pain
"We placed 12 separate POs to the same supplier last month. Freight costs were ridiculous."
Solve
PO consolidation dashboard with recommended lot sizes based on your actual demand data.
03

Procurement Behaviour Analytics

Are your buyers following the same process? We analyse purchasing patterns across officers to identify inconsistencies, training needs, and standardisation opportunities — without blame, just data.

Pain
"Some buyers always round up lot sizes, others don't. We have no visibility into who does what."
Solve
Procurement analytics dashboard showing patterns across officers, materials, and suppliers.
04

Spend Analytics & Supplier Performance

Understand where your money goes and how your suppliers perform. We consolidate ERP data into clear dashboards showing spend by category, supplier reliability, price trends, and savings opportunities.

Pain
"I can't tell you our total spend with any supplier without someone pulling a report for 3 hours."
Solve
Live spend dashboard — total spend, trends, supplier scorecards, all in one view.
Engineers reviewing analytics dashboards
Modernisation · Plant ops centre
01

Planning Tool Modernisation

Your planning system does the job, but the interface is outdated and reporting is clunky. We build a modern analytics and reporting layer on top of your existing tool — without replacing the core.

Pain
"Our planning tool has all the data we need, but getting a usable report out of it takes hours."
Solve
Modern dashboard on top of Infor / SAP / Oracle — presented the way your team actually wants to see it.
02

OEE Monitoring Tool Enhancement

Your OEE tool captures production data, but trending, comparing lines, or correlating with other sources requires manual effort. We connect OEE into a unified analytics platform alongside historian, quality, and ERP data.

Pain
"Our OEE tool gives us real-time data but we can't easily trend it or compare across lines and shifts."
Solve
Unified analytics that combines OEE + historian + quality + ERP into one view.
03

Data Integration Across Legacy Systems

Your plant runs on 5–10 systems that don't talk to each other — historian, SCADA, ERP, LIMS, CMMS, MES. We build pipelines that connect them into a single source of truth for plant performance.

Pain
"To answer a simple question, I need to pull data from 4 different systems and join them in Excel."
Solve
Automated data pipeline — all systems connected, one dashboard, refreshed daily.
04

Custom Digital Tools for Plant Teams

Sometimes the right tool doesn't exist yet. We build custom digital products for manufacturing teams — shift handover apps, quality event trackers, maintenance request tools, batch record digitisation — designed for the plant floor, not the office.

Pain
"We've asked IT for a simple tool for 18 months and it's still in the backlog."
Solve
Custom tool built and deployed in 3–5 weeks, not 18 months.
Operations team reviewing a problem together
Patterns · Wherever the work happens

The tabs above are where most of our work has been. But the problems underneath them repeat everywhere — any operation where the data is trapped, the tool goes unused, or the decision gets made on gut feel. If that sounds like your world, the sector matters less than you would think.

01

The numbers don't agree

Two systems, two answers, and a meeting that turns into an argument about whose spreadsheet is right. Nothing can be optimised until the data is trusted — so that is where we start.

Pain
"Every report says something different, so in the end we decide on gut feel."
Solve
One reconciled source of truth — with the logic visible, so your team can check it rather than take our word for it.
02

Someone built it and nobody uses it

The tool already exists. It was not cheap. It did not fit how the work actually happens, so the team quietly went back to Excel. The problem is rarely the technology.

Pain
"We already have the system. People just don't use it."
Solve
We start with the people doing the work, then rebuild around how they actually do it — keeping whatever of the old system still earns its place.
03

The same analysis, every single week

Someone capable spends a day a week rebuilding the same report by hand. It is the clearest signal there is that a tool is missing — and the easiest kind of work to hand back.

Pain
"My best analyst spends every Monday copying data between spreadsheets."
Solve
An automated pipeline and a tool that does it in seconds — so that day goes back to actual analysis.
OpenAI Select Partner

AI where it earns its place — and nowhere else.

We bring modern product management, digital transformation and data analytics — with AI applied only where it genuinely beats the alternative.

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OpenAI's global programme for firms that build and deliver AI with them — so what we build for you keeps pace with what the models can actually do.
01

No black boxes on your line

Every recommendation comes with the reasoning and the data behind it. Your process engineers need to agree with the logic before it changes anything — and if they can't follow it, we haven't finished the job.

02

Plain engineering when that's the better answer

Plenty of problems are solved properly by a clean data pipeline, a control chart, or a correctly configured planning parameter. We'll tell you when that's the case. AI goes in where the pattern is genuinely too complex for rules — not because it's on the brochure.

03

Your systems stay exactly as they are

We read from your historian, MES, ERP and quality systems. We don't modify them, we don't need a platform migration, and nothing we build blocks a future upgrade. No validated system is touched.

04

Built for teams who don't trust AI yet

Most of the operators and planners using our tools have seen a failed digital rollout. So we start with the boring, verifiable things — numbers that reconcile, reports that arrive on time — and earn the right to the clever part.

Packages

One problem. A few weeks. An answer you can act on.

Each package is a short, self-contained engagement aimed at one problem. We agree what success looks like and what it costs before you commit — no open meter, no rolling programme. Then we adapt the work as the data tells us more, and if week one says the problem is not the one we scoped, you hear it in week one rather than at handover.

Foundation
Data Foundation & Dashboard
Connect the systems holding your operational data — historian, SCADA, ERP, quality, planning — into one automated pipeline, then build the dashboard your team actually works from. On a plant that means OEE, yield and downtime; in supply chain it means coverage and service. Same build, different numbers.
Popular
Diagnostic
Problem Deep Dive
A focused investigation into one problem that keeps coming back — a yield loss, a quality deviation, a cost line nobody can explain, a service miss. Data-driven root cause, quantified, with a prioritised action plan at the end.
Build
Operational Analytics Product
A purpose-built analytics tool for one area of the operation. Our most common is inventory health — coverage, days-on-hand, shelf-life risk, excess stock, root-cause decomposition — but the same build works for quality, cost-to-serve or asset performance.
Decision Support
Planning & Parameter Health Check
For when the system makes a recommendation and your people override it. We compare what was advised against what was actually decided, then find the misconfigured parameters, lot-size rules and inconsistent behaviour sitting behind the gap.
Modernise
Legacy Tool Modernisation
A modern analytics and reporting layer on top of a system you are keeping — planning, monitoring, scheduling, whatever it happens to be. No rip-and-replace, no migration, and nothing that blocks a future upgrade.
Optimise
Optimisation & Simulation
Model the operation and test decisions before you commit to them — sequencing, changeover, capacity, resourcing. Discrete-event simulation and optimisation, run virtually, so the experiment does not cost you a shift.
Ongoing

Support retainer — we stay with the tool.

Your tools are live — and we're here when you need us. Pipeline monitoring, dashboard maintenance, issue resolution, and continuous improvements. Reach us any time; we respond within the SLA. Tiers are scoped to how many tools we support and how fast you need us.

Essentials
  • 1–2 tools / dashboards
  • 24h response time
  • Pipeline monitoring & alerts
  • Bug fixes & maintenance
  • Business hours support
Professional
Most common
  • 3–5 tools / dashboards
  • 8h response · 4h for critical
  • Everything in Essentials
  • Monthly enhancements & tuning
  • Extended hours support
Enterprise
  • 6+ tools / dashboards
  • 4h response · 1h for critical
  • Everything in Professional
  • Proactive recommendations
  • Priority scheduling
Why we're different

We build tools people actually use.

Most consultancies deliver a report and leave. Most analytics firms build a dashboard and throw it over the wall. We stay until the tool is part of your team's daily routine — and the numbers actually improve.

What typically happens
✕
Build first, ask questions later
Consultant assumes they know the problem, builds in isolation, presents at the end. It doesn't fit how your team actually works.
✕
Big reveal after weeks of silence
You don't see anything until the final presentation. By then it's too late to change direction without blowing the budget.
✕
Technically correct, operationally useless
The dashboard looks great in the demo. But the operator on the night shift can't figure it out, so they go back to their spreadsheet.
✕
Deliver and disappear
Handover meeting, a user guide nobody reads, and the consultant moves on. When something breaks, your team is on their own.
How we work
✓
We start by understanding your people
We sit with your operators, planners, and engineers to understand their actual daily workflow — not what the process document says they do.
✓
You see working software every week
No black box. We show you progress every week. If we're heading the wrong way, we course-correct early — before it costs time or money.
✓
Built for adoption, not just accuracy
A dashboard nobody opens is worthless. We design for the shift supervisor at 6am and the plant manager in the Monday meeting — not for a demo.
✓
We measure success by outcomes
Our job isn't done when the dashboard goes live. It's done when your team uses it daily and the numbers — OEE, yield, DOH, energy — actually improve.
A common concern

"But we have a major ERP upgrade coming…"

We hear this all the time. Corporate IT is planning a multi-year, multi-million-dollar transformation. Your plant is told to wait. But your problems are happening now — and the upgrade is always 18 months away.

The "wait for the upgrade" trap
  • The ERP upgrade takes 2–5 years. Your plant can't wait that long for basic visibility into OEE, inventory, or procurement.
  • The upgrade scope keeps changing. What was promised for Phase 1 gets pushed to Phase 3.
  • Even after go-live, the new ERP gives you data — not insights. You'll still need analytics on top of it.
  • Meanwhile, your team runs on spreadsheets, misses improvement opportunities, and loses money every month you wait.
Why our work complements IT's roadmap
  • We sit on top of your systems, not inside them. We read from your ERP, historian, and plant tools — we don't modify them. Nothing interferes with the upgrade.
  • When the new system goes live, our tools plug straight into it. Swap the old data source for the new — the dashboards, models, and optimisation logic carry over.
  • You'll be better prepared for the upgrade. The analytics you build now clarify real requirements based on real usage — not guesswork in a workshop.
  • Get results now, not in 3 years. A dashboard deployed in 4 weeks starts saving time immediately. That's 3 years of value you'd lose by waiting.

We don't compete with your IT transformation. We give your plant team the tools they need today — and when the upgrade arrives, everything we've built carries over seamlessly.

How we work

From first call to delivered results.

Engineering team reviewing operations data
01

Discovery Call

30 min · Remote

We listen. No sales pitch. We tell you honestly if we can help.

02

On-Site Visit

Half day · Your plant

We see your systems, data, and processes. Reality, not PowerPoint.

03

Problem-Led Proposal

2–3 pages

Built around the problem we actually found and the outcome you want from fixing it — not a frozen feature list. The problem and the outcome hold; how we solve them is free to improve as we learn.

04

Delivery

Weekly reviews

We build, you review every week, and we re-prioritise together on what moves the outcome. Minimal disruption to your team.

05

Handover

Documented + trained

Everything handed over. Your team trained. Ongoing support available as a retainer.

Case study

Two years embedded — across three functions, five plants.

Global Nutrition Manufacturer · Multi-site, APAC-focused

Embedded with manufacturing and supply chain teams — delivering digital products across plant operations, inventory management, and supply chain visibility.

We partnered with Abbott's manufacturing operations to build and deploy analytics tools across multiple functions — from plant floor OEE intelligence and loss diagnostics, to inventory health and shelf-life dashboards and end-to-end supply chain visibility. Plant-focused tools span five sites across three continents; supply chain and market-logistics tools serve Abbott's Asia-Pacific affiliate network. Used daily by plant operators, supply chain planners, and market teams — driving continuous improvement and operational visibility across the network.

Plants
Singapore Ireland Spain Netherlands China
Markets
Asia-Pacific affiliates
2
Years embedded
3
Functions served
Senior
Leadership endorsement
Daily
Active usage by teams
Plant OEE & Production Intelligence Inventory Health & Shelf Life Supply Chain Visibility Legacy Tool Modernisation
Get in touch

Your tools should work for your team —
not against them.

Book a free 30-minute discovery call. Whether it's disconnected plant systems, supply chain blind spots, procurement headaches, or market logistics visibility — tell us where it hurts and we'll tell you honestly whether we can help.

Book a discovery call → shiyan.su@prodthoughts.com