AMAI Technologies · production, online

Digital systems for manufacturing

We connect equipment, computer vision and production analytics into one management system.

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Line statusRunning
OEE82,3%
Output per shift35 180
Datain real time
Our products

What we build

Our flagship product shows the real state of production: output, OEE, downtime and its causes, in one live interface.

Flagship product

AMAI Efficiency

A digital control system for the production line. It collects events from equipment automatically, shows pace and output, logs downtime, and helps assign a cause and route the task to the right team.

  • A sensor kit and a local AMAItech module
  • A shift screen for line status and downtime causes
  • A management panel with OEE, losses and trends
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Household chemicals line L1data streaming in
OEE78,2%
Output31 445
Stop56 min
Line stateRunning
Telemetry: line signal is stable
The scenario shows the line running, stopping, and recovering

AMAI Signal

Predictive analysis and condition monitoring for industrial equipment: vibration, temperature, anomalies, failure forecasts and alerts.

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AMAI Vision

Computer vision for quality, completeness, labeling, object position and deviations on the production line.

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AMAI Sensor

Reusable sensors and transmitters for bioreactors: DO, pCO2, pH, foam and VCD, feeding your PLC and SCADA, serviced in Russia.

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AMAI Planning

Operational planning tools: equipment load, shift tasks, priorities, deviations from plan and execution tracking.

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AMAI Engineering

Modernizing, deploying and maintaining automated production complexes, with support at every stage from design through commissioning.

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AMAI Twin

A digital twin for your equipment and processes, kept in sync with plant sensors, for real time analysis and forecasting.

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One digital loop

From a line signal to a management decision

Each module solves one specific problem, and together they give a clear, real time picture of production.

4 problems across the industry

01No clear data on how equipment and lines are actually running
02Operational planning that is hard to keep current
03Deviations and defects found too late
04Dependence on manual judgement and imported equipment

Case studies

Applied projects on the shop floor, from computer vision to efficiency monitoring.

Computer vision

Case 1: computer vision

Checking the completeness of the can matrix for TD KUDO

ProblemGaps in the can matrix risked shipping short batches and drawing customer claims.

SolutionBuilt a computer vision system that flags missing cans in the matrix before shipment.

  • Installed a camera at the inspection point
  • Dataset collected and labeled
  • CV model trained
  • Built an operator alert system

Economic effect up to $116K/yr

Efficiency monitoring

Case 2: efficiency monitoring

For the TD KUDO production line

ProblemThere was no single system tracking line output, downtime and defect rate in real time.

SolutionBuilt a monitoring system with live key metrics and a Telegram bot for management.

  • Monitoring the stages of the line
  • Tracking throughput and downtime
  • Defect rate analysis
  • Live access to data through the interface and a Telegram bot

Less lost time through tracking downtime and its causes.

Continuous sensing

Case 3: bioprocess monitoring

One of the largest pharmaceutical manufacturers in Russia

ProblemThere was no continuous DO, pCO2 and VCD profile between lab samples, so process deviations were caught late.

SolutionInstalled inline measurement channels feeding the control system and the batch history in real time.

  • Continuous DO, pCO2, pH, foam and VCD readings
  • Data feeding straight into the control system
  • Faster reaction between lab samples

Economic effect $17K/yr

Control system modernization

Case 4: mixer modernization

One of the largest pharmaceutical manufacturers in Russia

ProblemA mixer ran from a local panel only, with no pH or conductivity readout, and mixing was done by hand.

SolutionKept the working mechanics and replaced the PLC and HMI, added remote control, pH and conductivity sensors, dosing pumps and a recipe algorithm.

  • Kept the existing tanks and mechanics
  • New PLC, HMI and remote control
  • pH and conductivity monitoring during the process

$116K below the cost of a full line replacement

Process control

Case 5: recipe execution

One of the largest pharmaceutical manufacturers in Russia

ProblemRecipe changes needed an engineer every time, and there was no per-step history of a run.

SolutionTied recipe execution to the PLC, with versioned recipes and a full step-by-step history.

  • Versioned recipes, changed without an engineer
  • Execution tied directly to the PLC
  • Full history of every step

Deviations down 15%, recipe changes 30% faster, $35K/yr

Production planning

Case 6: production planning

For the TD KUDO production line

ProblemThe schedule was built by hand without full visibility into orders, stock, deliveries or staffing.

SolutionCombined orders, stock, deliveries, resources and changeover rules into one planning model.

  • One planning model for the whole line
  • Recalculates when orders or resources change
  • Fewer manual pauses and changeovers

Economic effect $70K/yr

Get in touch, we are ready to work on your production problems

  • Phone: +7 977 810 70 33
  • Email: info@amaitech.ru
  • Website: amaitech.ru
  • City: Moscow, Russia
  • Hours: Mon to Fri, 9:00 to 18:00
  • Legal entity: OOO Amai Tech
  • Tax ID: 9726097408
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