Your Factory’s Future, Predicted in Real Time

Our Solutions

AI That Predicts Failures and Maximizes Uptime. Your Data. Your Factory. Your Rules. Zaptask AI runs 100% on your infrastructure or private cloud. No data ever leaves your control. Full on-premise or air-gapped deployment options available — total security, zero vendor lock-in.

Predictive Breakdown Prevention

Zaptask AI monitors vibration, temperature, sound, and 200+ parameters in real time. Our models predict failures up to 30 days in advance with 97%+ accuracy — giving your team time to act before a breakdown ever happens.

• Catch bearing failures weeks early

• Prevent motor burnout & spindle crashes

• Extend machine life by 25–40%

Real-Time Machine Monitoring

ive dashboards show spindle load, vibration trends, temperature spikes, cycle times, and tool wear in real time. Get instant alerts via app, email, or SMS the moment any parameter goes off-spec.

• One unified view for 10 or 10,000 machines

• Mobile + desktop + shop-floor displays

• Color-coded health status (green/yellow/red)

Zaptask AI constantly analyzes cycle times, bottlenecks, and throughput across your entire line. It auto-adjusts parameters, reallocates jobs, and predicts optimal scheduling to squeeze every possible minute out of your floor.

• Boost OEE from 65% → 85%+ in weeks

• Reduce changeover time by up to 60%

• Eliminate micro-stops before they add up

Production Line Optimization

AI Quality Control – No New Cameras Needed

Zaptask AI analyzes your existing machine data (torque, pressure, cycle time, temperature, etc.) in real time. When the exact “fingerprint” that caused past defects appears again, we flag the part instantly — before it moves to the next station or ships.

• 50–80% reduction in customer returns

• Works with your current PLCs/MES/ERP

• Live in weeks, not months

• Zero new hardware required

Smart Inventory & Demand Forecasting

Zaptask AI combines your sales history, ERP data, supplier lead times, and external signals (market trends, seasonality, even weather) to predict exact material needs weeks ahead.

• Cut excess inventory by 20–50%

• Eliminate production stops from missing parts

• Auto-generate perfect purchase orders

• Frees up millions in working capital

Dynamic Production Scheduling

When anything changes — late shipment, rush job, machine issue — Zaptask instantly re-optimizes the entire floor schedule. Prioritizes hot orders, minimizes changeovers, and keeps every line running at peak.

• 15–35% higher throughput

• Changeovers slashed by up to 60%

• Real-time “what-if” scenarios for planners

• Works with your existing MES/ERP

Zaptask AI cut our downtime by half with its sharp predictive alerts.

J. Lee

★★★★★

Quick Answers

How does AI help?

AI predicts failures early, cutting downtime and boosting efficiency.

Is real-time monitoring included?

Can it optimize production?

What about automated maintenance?

Does it support quality control?

Yes, machines are tracked live to catch issues instantly.

Absolutely. AI analyzes data to streamline workflows and improve output quality.

The system schedules upkeep automatically, preventing unexpected breakdowns.

Yes, AI detects defects early to maintain high product standards.

Get a Free Consultation

Reach out to us anytime for support or questions about ZapTask AI.

Phone

+1-937-807-4521

Email

info@zaptaskai.com