Phone capture
- Standard phones and our app
- 3D photogrammetry rebuilds your station
No CAD files needed
Non-invasive factory digital twin · US, Latin America & beyond
Your floor is losing money. We find where, then bring the robot AI that fixes it.
We price every loss on your line, from scrap to downtime to a slow PLC cycle, rebuild your worst station as a digital twin using phones and plug-in sensors, and test fixes in it until one hits the target you set. You pay only if it hits that target on your real floor.
Non-invasive: no PLC accessNDA firstAny brand you runPay only if it hits the target
What is your line losing?Your numbers
You're losing about
$1,152,000
a year. Cutting it by 30% is worth $345,600 a year.
Find my real number, free →
Move the sliders to your plant. The loss check replaces these guesses with measured numbers.
Expert network from
Non-invasive by design
Most digital twins are a rearview mirror. Ours runs alongside your line.
Traditional twins take months of IT integration and big upfront budgets, then show you a dashboard of what already happened. We rebuild your station in days, without touching your systems, and use it to test what happens next.
Plug-in sensor kit
- Cameras, acoustic, thermal and vibration sensors
- Clipped on alongside equipment
Removed when we leave
Your systems untouched
- We never touch your PLC code
- Nothing connects to your network
Our kit runs on its own network
Us or a local partner
- Remote-first: we ship the kit and guide your team by video
- When a visit helps, our team or a local partner comes on site with PPE and completes your induction
Works around your shifts
Whatever you run. All welcome.
PLCsSiemens · Allen-Bradley (Rockwell) · Mitsubishi
RobotsABB · KUKA · FANUC · Yaskawa
Simulation toolsRobotStudio · KUKA.Sim · ROBOGUIDE · TIA Portal · NVIDIA Isaac Sim
Everything elseVision, conveyors, fillers, mixers, drums, any make
We don't sell any brand. Names are trademarks of their owners; AIChamp is independent and not affiliated with them.
What you get
A report your COO can sign. In your hands in 14 days.
Losses hide in maintenance, production, programming, engineering and safety, each with its own language. The report translates all of it into dollars, flags bottlenecks and best practices, and ranks the fix that pays back first. This is the format of the free loss check report.
Loss report · Line 2 · 14-day captureSample
Loss found
$2.1M / yr
Fixable in year one
$740k
Fastest payback
5 mo
| Where | Loss | Cost / yr | Best fix tested in twin | Payback |
|---|---|---|---|---|
| Batching | Bad batches | $960,000 | Dosing check at the mixer, tank or drum + recorded SOP | 5 mo |
| Grading | Mis-grades | $610,000 | Vision grading at inspection | 7 mo |
| Trim & cut | Scrap | $380,000 | New cut pattern, no robot needed | 2 mo |
| Pack-out | Injuries, open shifts | $150,000 | Fixed arm cell (humanoid ranked last) | 13 mo |
Each row is a candidate fix. Pick one, set the target it must hit, and it is tested in your twin before anything touches your line.
- Maintenance"4 hours of conveyor downtime" becomes $14,000 lost.
- Programming"A 2-second PLC delay" becomes $5,000 a month.
- Safety & scrapEvery loss gets a price, so spend $5,000 to save $50,000 is an easy yes.
How it works
One number. Measured the same way. Before and after.
No marketing math. We agree on one KPI, measure it on your line before anything changes, and measure it the same way after. Both sides sign the result.
- WEEKS 1–2 · MEASURE
Capture & baseline
Phones and plug-in sensors go up alongside production, set up by your team with us on video, or on site by us or a local partner. You get every loss in dollars and a baseline for your KPI.
- WEEK 3 · AGREE
Target in writing
One page: the KPI, how it's measured, the variables (quality, dimensions, speed) and the price if it's hit.
- WEEKS 4–10 · PROVE
In the twin
We build the twin, then robot-AI teams, PLC changes, vision and equipment options are tested in it. Nothing touches your line.
- AFTER · CONFIRM
On your floor
The fix is installed by your integrator, or by us or a local partner, then measured with the same sensors and method. Hit it: you pay the agreed price. Miss it: you pay nothing.
Target sheet · BatchingSample
KPIBad batches, % of batches
Measured byDosing sensors + lab results, every batch
Baseline (2 weeks)3.1%
Target (30 days at line speed)under 1.0%
Pilot result0.8% ✓ target hit
Plants like yours
Different floors. Same leaks.
Where raw materials vary and one wrong step can ruin a batch, money leaks in the same few places. Here is where we look first.
- Meat, poultry & hidesFirst fix tested: vision check at the trim table
- Dairy & ice creamFirst fix tested: fill-weight check at the filler
- Corn syrup & millingFirst fix tested: dosing check at the tank
- Beverages & bottlingFirst fix tested: dosing check in the mix room
- Bakery & snacksFirst fix tested: portion-weight check
- Chemicals & coatingsFirst fix tested: recorded dosing SOP
- Leather & textilesFirst fix tested: vision grading + new cut pattern
- Your lineIf one bad batch costs real money, it works the same way.
How you pay
Free to find. Pay only when it works.
We're vendor-neutral. Fixes from any maker are tested in a twin of your station against the target you set, before you spend capex, and you pay only if the fix hits it.
Step 1 · Loss check
$0
Every loss on one line, priced in dollars.
- Loss report in dollars, station by station
- The fixes worth testing, ranked by payback
- Non-invasive: phones and plug-in sensors, no PLC access
- NDA signed before any sensor goes up
- You keep the report either way
Your footage and data belong to you and stay in your control.
Step 2 · Test, then fix
On target
You set the bar. You pay only if the fix clears it.
- Every option tested in a twin of your station before capex
- Robots, PLC logic, AI quality cameras, equipment or process: whatever pays back first
- Vetted robot-AI teams train on your task in the twin
- Vendor-neutral: we don't sell brands
- Pilot on your floor, measured against your target
- Hit the target: you pay the price agreed in writing
- Miss the target: you pay nothing
Optional after the pilot: keep our AI quality cameras on the line to keep measuring.
We already work with an integrator or vendor. Why add you?
Keep them. We don't sell robots or software, and we run alongside your quality systems. We test their proposal in a twin of your station first, so you know it pays back before you sign. If their fix wins, they build it. Integrators use it too: prove your proposal before the customer signs.
We already track OEE. What does this add?
OEE shows availability, performance and quality. We feed your OEE into the twin, or measure it at any point on the line, and turn every lost point into dollars, including what machine counters miss: manual steps, batching, grading and trim. You see the whole balance.
Who sees our data?
Only the team on your line sees it, under an NDA signed before any camera goes up. We measure stations, not people: faces are blurred and there is no individual performance tracking. Our cameras and sensors run on their own network, nothing connects to your systems or PLCs, and your footage and recipes stay yours.
What do we commit to?
One page: the task, the KPI and how it is measured, the target (say under 1% bad batches at line speed) and the price if it is hit. Hit it on your floor: you pay the agreed price. Miss it: you pay nothing.
San Francisco · Mission Bay
Show us the line that costs you most.
We see every new robot first. Robot-AI teams from our San Francisco network train on your task, so you get the best one, not the one a vendor is pushing.
Bring to the 20-minute call
- The line or step that hurts most
- A rough number from the calculator above
- One task you'd pay to have done right every time
- Not sure where it hurts? That's what the loss check finds.
Prefer email? Send us the station that costs you most:
[email protected]