Building your factory’s brain that works across every shift.
We identify your biggest manufacturing losses, diagnose and fix them: reducing operator touches by 70% and making diagnosis and correction 8x faster.
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The problem
The line already knows how to fix itself. It just can’t remember.
01
Tribal knowledge is a single point of failure
of the US manufacturing workforce retires by 2030 — 1.5M+ roles at risk
of manufacturing know-how is undocumented, held only in people's heads
India faces the same gap as a shortage instead: ~150M skilled workers short.
02
Root cause analysis happens. The knowledge still disappears.
Downtime gets diagnosed, but the fix stays scattered across SOPs, manuals, and shift notes — never centralized into one brain for the plant.
lost weekly to unplanned downtime, globally
of manufacturers had unplanned downtime in the past year
03
The data already exists. It's just not used.
Your PLCs, sensors, and cameras already capture what's needed — the gap is a system that reads it like an experienced operator would.
of sensor data is never used at all
of manufacturing process data goes unused
How it works
Three products — pick what fits your manufacturing
Each layer works on its own and builds toward the next. Start wherever makes the most sense for your plant’s priorities and digital maturity.
Data partnership — plants generating unique operational datasets may also license that data to us on a separate, optional basis. Ask about terms.
See it in action
Same fault. Two very different shifts.
A drive shaft fails on Motor 5 of the labeling line. Here’s what happens next — with and without ForemanLab.
Without ForemanLab
Elapsed downtime
- —Line stops. The labeling line is down.
- —Operator walks the line, checking each PLC for the fault.+15 min
- —Traces it to one transformation on the labeling line.+10 min
- —Reads the HMI screen for the alarming component.+5 min
- —Inspects by hand — Motor 5 drive shaft is damaged.+10 min
- —Calls around for the part number, stock, and procedure. Walks to inventory.+45 min
- —Waits for a senior operator to explain the replacement.+25 min
- —Shaft replaced. Line restarts.+10 min
With ForemanLab
Elapsed downtime
ForemanLab
Line assistant · Labeling line
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FAQ
Answering your biggest concerns
No. Detect & Diagnose runs on your existing downtime data, operations metrics, and line cameras. Prediction reads from the PLCs, historians, sensors, and cameras you already have.
No. Detect & Diagnose, Prescription, and Prediction are each sold and deployed independently. Most plants start with a diagnostic, then move to Prescription once it's proven out.
Detect & Diagnose takes one week. Prescription takes four weeks. Prediction takes eight weeks.
Operators share their expertise in voice or text, in whatever language they're comfortable with, over a simple messaging interface — no app to install.
It shares a ranked probability of the likely root causes instead of guessing, and escalates automatically to the right person on your team using your plant's organizational structure if it can't resolve it.
Founder
Built by someone who’s stood on the line
Shubhanshi Asati
Founder, ForemanLab
IIT Bombay, Batch 2022 · shubhanshiasati@gmail.com
Hyderabad, India · Prague, Czech Republic
4+ years deploying deeptech use cases across the biggest manufacturing sites with P&G in India, Central Europe, and the US.
Ready when you are
Find out what your biggest loss is actually costing you
Book a demo to get a prioritized value stream mapping, loss ranking, and transformation roadmap.