$1.3M a year in downtime.
One packaging line.
$2.9M recovered in five years.
AI-powered downtime elimination for frozen food processing. See how one plant turned 1,305 hours of unplanned downtime into a 496% return on investment — without adding headcount or replacing equipment.
This is what one packaging line costs
when it goes unplanned.
on a single line
operating & margin losses
your team standing idle
if nothing changes
Every hour this line goes down, $996 walks out the door — $419 in operating costs that keep burning while nothing moves, plus $577 in product that should have been packed and shipped. That's 8 people standing idle every time the line stops. Multiply it by 1,305 hours a year. And 85% of those lost hours require overtime to recover — at 1.5x labor rates. That's not a rounding error. That's a line item your CFO can't ignore.
You've tried fixing downtime before.
Here's why it didn't stick.
Most systems depend on operators selecting fault codes from dropdown menus during a stoppage. Under pressure, they pick the fastest option, not the right one. Your downtime data is only as good as what gets entered — and it's almost never the real story.
You bought a monitoring system. Now you have 400 fault codes per machine, 12 dashboards nobody checks, and a weekly report that tells you what you already knew. Visibility without root cause is just expensive noise.
Wait for it to break. Rush to fix under pressure. Miss the actual cause. Watch it break again. The cycle costs more every time it repeats — in parts, in labor, and in the production you'll never get back.
Traditional CMMS and MES rollouts take 6–12 months before anyone sees a result. By then, priorities shift, champions move on, and the system becomes another underused tool with a subscription fee.
Not another dashboard.
A complete system that works.
Ai.Downtime reads directly from your PLCs, sensors, and fault registers. Sub-second timing. Automatic root cause identification. No dropdowns, no guesswork, no line slowdowns. The data is right because the machine told us — not because someone remembered to log it.
Instead of 400 raw fault codes, you see the one initiating cause that started the cascade. Every fault event is interpreted into plain language your team can act on, with the production impact quantified automatically.
Data alone doesn't fix anything. Ai.Downtime includes the Downtime Reduction Sprint — a structured daily process that brings maintenance and production together. And when it's time to execute the fix, the right SOP or troubleshooting guide is delivered directly to your tech's device.
Phased rollout starts recovering production hours in Month 1. No 6-month implementation runway. The system works with your existing PLCs and sensors — no rip-and-replace.
One packaging line. One deployment.
Here's what happened.
paid for itself
a single line
recovered
Starting from 1,305 hours of unplanned downtime per year and $1.3M in annual losses on a single packaging line, this frozen food processor achieved an 81.4% total downtime reduction across three improvement stages. The system delivered $3.6M in total benefits against a $726K total investment over five years — paying for itself in just over a year.
Quick definitions: Total benefits are the gross savings and recovered margin the line generates from reduced downtime. Net return is what’s left after subtracting the total investment.
55% of addressable downtime eliminated
45% of remaining addressed
25% of remaining + optimization
“We always knew downtime was costing us, but we couldn't tell anyone exactly how much or where to start. Now the data shows the team exactly where to focus — and the results speak for themselves.”
— Plant Operations, Frozen Food Processor, Pacific Northwest
See exactly what unplanned downtime is costing
your frozen food operation — and how fast
you can start recovering it.
One packaging line. One deployment. Measurable results in weeks, not months.