Consulting & diagnostics
We analyse processes, assess data and identify suitable AI opportunities. We define the objective before choosing technology.
Service / 01
AI & production optimisation
Data. Decisions. Efficiency.
We measure production effectiveness, address losses with Lean methods and implement AI where it can deliver a measurable result.
From assessment to a working solution
AI integration
A tailored AI strategy
We select tools and plan resources and training. Individual initiatives are aligned with the longer-term digitalisation plan.
Implementation & optimisation
We develop AI solutions and integrate them with existing systems. We verify results and plan monitoring, maintenance and further development.
Potential depends on the task
Where AI can help
Efficiency & cost
- Automating routine tasks
- Finding inefficiencies through data
- Reducing errors in repetitive operations
Better decisions
- Analysing large datasets
- Forecasting workload and trends
- Decision support with human oversight
Product development
- Supporting idea generation and evaluation
- Automating repetitive development tasks
- Faster access to technical knowledge
Service & knowledge
- Assistants for questions and internal procedures
- Easier access to instructions
- Context-specific support
Production optimisation
Data. Decisions. Efficiency.
01 / Data
We measure OEE, downtime, scrap and bottlenecks. If data is missing, we start manually and automate where justified.
Output: baseline indicators and a loss map in euros
02 / Decisions
We prioritise measures by impact and investment: organisational improvements first, then suitable technology.
Output: a prioritised plan, budget and payback estimate
03 / Efficiency
We compare results against the baseline and sustain improvements through standards, training and maintenance.
Output: a before-and-after report on agreed indicators
When to start
Signs that production is losing capacity
Unknown actual OEE
Reliable data on the time equipment produces good output is missing.
Scrap & complaints
Nonconformities are discovered late, at final inspection or by the customer.
Downtime & changeovers
Capacity is below nominal and loss reasons are not recorded.
Delayed reporting
Decisions rely on manually collected data from previous days.
People & knowledge gaps
Setup and troubleshooting depend on a few key employees.
An upcoming investment
A new machine, modernisation or automation requires a clear investment case.
Service scope
Four modules, combined to suit the task
Each project starts with analysis. Other modules are included according to the needs identified.
Analysis & measurement
- OEE measurement and baseline indicators
- Value stream mapping (VSM)
- Analysis of bottlenecks, downtime and scrap
- Quantifying losses in euros
Lean optimisation
- 5S and visual management
- SMED: reducing changeover time
- TPM: autonomous and planned maintenance
- Standardised work and Six Sigma for consistent quality
AI solutions
- Real-time effectiveness monitoring
- Visual quality inspection
- Predictive maintenance
- Operator assistants, reporting and planning
Training
- AI in manufacturing for managers
- Lean and OEE for process engineers and team leaders
- Team training with each implementation
Why automate now
Your team is doing work an AI agent could handle — it is time to assess the opportunity.
Imagine 30–50% of your operations team’s time going into copy-paste, document review, ticket routing and inbox sorting. Specialised AI agents, integrated with CRM and ERP and supervised by your team, can take over part of these tasks.
We start with a specific task and a limited pilot rather than a months-long transformation. We check the actual cost per task, quality and time saved before expanding the solution.
€0.02
Illustrative scenario: AI cost per task versus €4–€12 for manual processing. Integration, review and maintenance are assessed separately.
70%
Target automation of the selected set of repetitive tasks — validated through assessment and a pilot.
2–4 weeks
Target time from kickoff to a pilot agent, with data and access ready and a clearly defined scope.
Typical applications
Applications with an operational purpose
Potential applications depend on the process and equipment. These are not published client case studies.
Effectiveness monitoring
Machine availability, performance and quality data, with downtime reasons.
We track: OEE and downtime
Visual quality inspection
Cameras and AI models selected for the product, lighting and inspection requirements.
We track: Scrap and complaints
Predictive maintenance
Analysis of vibration, temperature and current for early warnings of condition changes.
We track: Unplanned downtime
Digital operator assistant
Bulgarian instructions, procedures and troubleshooting support on a terminal or smartphone.
We track: Training and errors
Automated reporting
Shift and management reports generated from production data without duplicate manual entry.
We track: Reporting time
Planning & forecasting
Forecasting workload and supporting production scheduling against orders.
We track: Capacity and lead times
From assessment to implementation
Working together
Scope and investment are defined after reviewing the actual process.
- 01
Introductory meeting
60–90 minutes on site or online to discuss objectives, constraints and priorities.
- 02
Process assessment
1–3 days in production to measure losses and establish baseline indicators.
- 03
Technical proposal
A solution, schedule, budget and payback estimate based on available data.
- 04
Implementation
Phased implementation and verification of agreed indicators.
- 05
Support & development
Team training, support and periodic review of results.
Practical answers
Questions before we start
What does OEE measure?
OEE is overall equipment effectiveness: availability × performance × quality. We combine it with loss reasons to decide where improvement should start.
Do we need existing data to start?
No. We review available reports and signals. If reliable data is missing, we start with manual or automatic measurement to suit the equipment.
Is AI always needed?
No. We assess the process and organisational improvements first. A Lean change, machine adjustment or better measurement may solve the problem without AI.
Can we start with one line?
Yes. A pilot has a limited scope, a baseline and success criteria agreed in advance.
The next step
Request an assessment
Modernization and retrofit · Sliven
+359 889 925 363office@vesmar.eu8 Yane Sandanski St., Sliven, BulgariaDescribe the process, challenge and desired result. You can email us directly or prepare your enquiry here.
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