SYSTEM
ARCHITECTURE
TECH STACK
Core Engine
- > React + Vite (Industrial Dashboard)
- > TensorFlow.js (Edge Inferencing)
- > WebRTC (Real-time Video Stream)
- > PWA Service Workers (Offline Core)
Cloud & AI
- > Vercel Edge Network (Global CDN)
- > Google Gemini 1.5 Pro (Multimodal Logic)
- > MediaPipe (Hand/Body Tracking)
- > Supabase (Vector Embeddings)
COMPLIANCE & STANDARDS
| Standard | Description | Status |
|---|---|---|
| ISO 9001:2015 | Quality Management Systems (Documentation Auto-Gen) | COMPLIANT |
| OSHA 1910 | Occupational Safety (Ergonomic Risk Analysis) | COMPLIANT |
| GDPR Industrial | Face-blurring on operator video streams (Privacy) | ACTIVE |
| ISA-95 | Integration with ERP/MES (SAP, Oracle) via API | BETA |
INTELLIGENT DASHBOARD ARCHITECTURE
Real-time Production
Monitoring of actual units vs. targets with dynamic bar charts and efficiency heatmaps.
- > Shift Target Tracking
- > Botleneck Identification
- > Efficiency Variance
Operational Absenteeism
Financial impact analysis based on hourly wages and operational downtime.
- > Direct Labor Loss ($)
- > Capacity Reduction %
- > Critical Skill Backup
Quality & Scrap
Scatter chart analysis of rejects with immediate scrap cost calculation.
- > Scrap Cost Analysis ($)
- > Defect Clusters
- > Rework Impact Tracking
User-Defined Parameters
Engineers can define real cost parameters (Wage/hr, Efficiency, Scrap Cost per Unit) in Settings to drive the financial logic of the dashboard.
AI ANALYSIS METHODOLOGY
How Gemini Analyzes Operations with Only 6 Frames
Video Processing Limits
- > Maximum Duration: 2 minutes
- > Frames Extracted: 6 frames (distributed uniformly)
- > Image Quality: JPEG 0.8 compression
- > Token Optimization: ~85% reduction vs. full video analysis
Analysis Pipeline
-
01
Sequence Recognition: The 6 frames capture the complete operation cycle (start → intermediate steps → finish). AI identifies the operation type and phase transitions.
-
02
Movement Detection: Computer vision tracks hand/body position changes between frames to calculate distances, angles, and complexity (finger count, rotation, precision required).
-
03
Standard Time Database Matching: Detected movements are matched against industrial time standards:
- • Motion Analysis: "Reach 30cm = 0.8s"
- • Standardized Work: "Straight stitch @ 2500 RPM = 2.1s/15cm"
- • Fundamental Movements: 18 basic motions with predefined times
-
04
Intelligent Inference: AI fills gaps between frames using ergonomic models and industry knowledge (e.g., typical machine speeds, operator fatigue patterns, micro-adjustments).
Example Analysis
VISUAL INPUT:
- Frame 1: Hand 40cm from fabric
- Frame 2: Hand grasping fabric
- Frame 3: Fabric under presser foot
- Frame 4: Needle stitching
- Frame 5: Operator removing piece
- Frame 6: Finished piece on table
AI INFERENCE:
- Reach 40cm → 1.2s
- Grasp thin fabric → 0.4s
- Position under foot → 1.5s
- Stitch 15cm @ 2500 RPM → 2.1s
- Remove + Release → 0.9s
- TOTAL: 6.1 seconds
Accuracy & Limitations
PRECISION:
- ✓ Typical variance: ±10-15%
- ✓ Sufficient for: Inefficiency detection, operator comparison, layout optimization
- ✓ Best for: Repetitive operations with clear phases
NOT SUITABLE FOR:
- ✗ Legal time-study documentation (requires continuous recording)
- ✗ Micro-motion analysis (<0.1s precision needed)
- ✗ Highly variable operations (custom assembly, R&D)
INDUSTRY KPI MATRIX
Automotive
- OEE Overall Equip. Eff.
- SCRAP Material Waste %
- TAKT Cycle Time Match
Aerospace
- COMP Compliance %
- TRACE Traceability Score
- VAR Standard Variance
Electronics
- YIELD Pass Rate %
- FAIL Comp. Failure %
- UPH Units Per Hour
Textile
- SMV Std Minute Value
- DHU Defects per 100
- UTIL Fabric Utilization
Footwear
- PPH Pairs Per Hour
- SEW Stitching Eff.
- YIELD Leather Yield
Pharma
- BATCH Cycle Time
- Compliance Compliance %
- DEV Compliance Variance
Food & Bev
- Safety Critical Points
- SPEED Bottling Rate
- SEAL Quality Integrity
Metalworking
- CNC Runtime Efficiency
- WEAR Tool Health
- CPK Dimensional Acc.
MARKET OPPORTUNITY
Total Addressable Market (TAM) Analysis 2024
Global Footprint
Revenue Projection (Year 1)
Industry Breakdown
🚗 AUTOMOTIVE
55% Asia✈️ AEROSPACE
45% N.America⚡ ELECTRONICS
70% Asia🧵 TEXTILE
75% AsiaGo-to-Market Priority
🎯 Tier 1: Asia
Largest TAM, rapid digitalization. Focus: China, India, Vietnam, Thailand
💰 Tier 2: North America
High tech adoption, premium pricing. Focus: USA, Mexico
🏆 Tier 3: Europe
Quality focus, compliance-driven. Focus: Germany, France, Turkey
COMMERCIAL SPECS & ONBOARDING
Factory Floor Package ($2,499/mo)
Capacity
- Lines: 10 Max
- Studies: Unlimited*
- History: 12 Months
User Roles
- Admins/Eng: 5 Seats
- Viewers: Unlimited
- Invites: Enabled
Support
- SLA: 24h Response
- Setup: Guided
- Training: Video Hub
Totally flexible configuration within the 10-line limit.
Client Onboarding Process
Purchase
Client subscribes via Stripe. Account created automatically.
Admin Setup
Admin defines factory layout and invites 4 other engineers.
Connect
Engineers connect RTSP cameras or mobile devices to lines.
Calibrate
Run 2-min calibration video. AI learns operations.
Analyze
Dashboards populate with real-time efficiency data.