AI Operations Infrastructure · Manufacturing MSME

Your plant is profitable on paper. Then the leaks take their cut.

Slow quotes that lose orders. MIS reports built by hand every morning. Scrap nobody reconciles. Breakdowns nobody saw coming. We build integrated AI systems that close these leaks — not chatbots, not one-off tools.

Bring one process. Leave knowing what it's costing you. No pitch, no slides.

86%
of manufacturers lose deals to slow quoting¹
~20%
of revenue lost to poor quality on average²
30–50%
less unplanned downtime with AI-assisted maintenance³
1 day/wk
lost per knowledge worker just finding information⁴
The Four Leaks

Nobody steals from a plant in crores. It leaks in lakhs, every single day.

Every leak below is invisible in the P&L until you go looking. Each one is a process your people run manually — and each one is a process an AI agent can run better.

Leak 01 · Sales

The quote that went out two days late

A single part can take up to two hours to price, and 43% of shops still quote in Excel. Meanwhile the buyer awarded the job to whoever answered first. You never even knew you lost.

Source: Paperless Parts / Symphona RFQ research
Leak 02 · Reporting

The MIS that takes your best people hostage

Every morning, someone senior spends hours compiling production data by hand — from SAP exports, registers, and WhatsApp messages. Knowledge workers lose roughly a day a week just gathering information.

Source: McKinsey Global Institute
Leak 03 · Quality

The scrap nobody reconciles

Cost of poor quality averages around 20% of revenue. On a ₹100 crore plant, that's ₹20 crore a year quietly walking out through rework, rejection, and warranty — while NCRs sit in a register.

Source: industry quality-cost research (iFactory / Deloitte)
Leak 04 · Maintenance

The breakdown everyone saw coming — except the system

Reactive maintenance means the machine tells you it's failing by failing. Plants running AI-assisted maintenance report 30–50% less unplanned downtime and 18–25% lower maintenance cost.

Source: Siemens / GE / Deloitte published results

Here's the uncomfortable arithmetic: while 78% of organisations now "use AI", only about 6% capture real financial value from it. The rest bought a chatbot, ran a pilot, and went back to the old way. The gap isn't technology — it's that patchwork tools don't survive contact with a real shop floor. Systems do.

The System, In Three Stages

One integrated AI operations layer. Installed in stages, proven at each one.

You don't buy a transformation on day one. You start with the leak that hurts most, prove the saving in writing, then expand. Every stage runs on your existing SAP, Tally and Excel data.

Stage 1 · Prove It

Operations Ignition

  • 24/7 enquiry & RFQ-capture agent on WhatsApp — no lead dies overnight
  • RFQ-to-quote drafting from your own pricing logic; your team approves, then it goes out in minutes
  • Daily production / MIS report compiled and delivered automatically — no human hours
Built for: the owner-run plant drowning in manual quoting and morning report-building.
Stage 2 · Extend It

Growth Engine

  • Everything in Stage 1, plus
  • Order-status & delay-alert agent — customers stop calling to ask "where is my order?"
  • Quote follow-up and receivables follow-up on autopilot — quote-to-cash tightens
  • Maintenance alerts, PM scheduling and a living breakdown log
  • A shop-floor knowledge assistant trained on your SOPs — in Telugu and English
Built for: the growing MSME scaling beyond what the founder can personally supervise.
Stage 3 · Run On It

AI Operations Cell

  • Everything in Stages 1 & 2, plus
  • A unified live dashboard — production, quality, maintenance and sales KPIs in one place
  • Complaint / NCR intake that drafts 8D & CAPA documentation automatically
  • Outbound lead-generation agent + management-by-exception alerting
  • White-glove training and quarterly optimisation
Built for: the ambitious plant ready to run operations on a system, not on memory.
Systems We've Already Built

Not theory. These systems already run on real shop floors.

Our founding team spent 16 years inside sheet metal fabrication, roll forming, aluminium extrusion and plant operations — and built these systems in production environments before Tejas AI Systems ever took a client.

System · SAP Analytics

SAP raw data → live cost dashboard

Takes raw SAP material-movement exports (MB51) and turns them into a self-contained expense dashboard — SLoc-wise KPIs, Pareto charts, one-click Excel and PPT export. Runs fully offline behind a corporate firewall.

Output: consumption visibility that used to take a day of Excel work, in minutes.
System · Shift Reporting

Automated OEE shift summaries

A three-shift, six-line automated reporting flow that reads production data, computes OEE, and delivers a formatted shift summary to Telegram and Teams — before the morning meeting starts, with no human compiling anything.

Output: the morning MIS, built and delivered while the plant sleeps.
System · Shop-Floor AI

Bilingual shop-floor assistants

Voice and chat assistants for operator learning and a structured suggestion-capture system — built bilingual in Telugu and English, because that's what a real Andhra shop floor speaks. Plus production schedule tracking and attendance automation.

Output: tribal knowledge captured; operator questions answered without hunting for the supervisor.

These systems were designed and deployed by our founding team in live manufacturing operations. Industry figures cited on this page (¹ Symphona/Paperless Parts RFQ research · ² iFactory/Deloitte quality-cost research · ³ Siemens/GE/Deloitte published maintenance results · ⁴ McKinsey Global Institute) are from published research, not Tejas client engagements — we tell you plainly which is which.

₹→

The only guarantee that means anything: a written ROI target, before you commit.

Every engagement starts with a 4-week single-agent pilot carrying a written savings target — in rupees or hours, agreed before we begin. If the pilot doesn't show measurable movement against that target, you don't continue, and you keep everything we built. No lock-in, no retainer trap.

Security & Integration

Your data never becomes someone else's training set.

We've worked inside plants with corporate firewalls, on-prem SAP, and IT teams that say no by default. We design for that reality.

On-premise & self-hosted options

Automation workflows can run self-hosted inside your network. Dashboards can be built fully self-contained — no external calls, no cloud dependency — for plants where data cannot leave the building.

Works with what you already run

SAP exports, Tally, Excel registers, WhatsApp, Teams, Telegram — we integrate at the layer your plant actually uses. No rip-and-replace, no six-month ERP project, no consultant army.

Human approval where it matters

Quotes, customer messages and quality documents are drafted by AI and approved by your people. NDAs standard, access logged, and every agent has a clearly defined boundary of what it may and may not do.

Straight Answers

The questions every MD asks. Answered without fog.

My team is not technical. Will they actually use this?+
That's precisely why we build on the channels your people already use — WhatsApp, Telegram, Teams, voice — and in the languages they actually speak, including Telugu-English bilingual assistants. If your supervisor can send a WhatsApp message, they can use these systems. Training is included in every stage, and adoption is our problem to solve, not yours.
We already tried a chatbot / automation vendor. It died in a month. Why is this different?+
Because a standalone tool has no roots. It answers questions but touches no workflow, so nobody depends on it, so it dies. We build systems wired into the processes money flows through — quoting, reporting, maintenance, collections — with a named owner and a measured KPI for each one. That's also why we start with a pilot carrying a written ROI target: if it doesn't move a number you care about, it deserves to die, and you'll know inside four weeks instead of after a year of fees.
How do I know the ROI is real and not consultant math?+
Two ways. First, the target is agreed in writing before the pilot begins — in rupees saved or hours recovered, measured against your own data, not ours. Second, we measure from your existing records (SAP movements, quote logs, breakdown registers), so the baseline is yours and auditable. If the number doesn't move, you stop. That's the whole arrangement.
Will this disrupt production or need a big IT project?+
No. We integrate at the data-export and messaging layer — reading SAP/Tally/Excel outputs and delivering through WhatsApp or Teams — not by modifying your core systems. Nothing we install can stop a machine or block a transaction. Typical deployment is measured in weeks: discovery in week 1–2, the first agent live by week 3–4.
Is my costing and customer data safe?+
Your pricing logic and customer data are treated as what they are: the crown jewels. Self-hosted deployment options keep data inside your network, NDAs are standard from the first conversation, and access to every system is logged. We've built for plants where the firewall blocks everything — fully offline dashboards included — so "our IT won't allow it" is a design constraint we already know how to satisfy.
What happens on the audit call? Is it a sales pitch?+
No slides, no pitch. You bring one process — quoting, MIS, scrap, maintenance, collections — and thirty minutes later you know roughly what it's costing you and what an AI agent could recover, whether or not you ever work with us. If there's a fit, we'll propose a pilot. If there isn't, we'll tell you that too.
Next Action

The leaks don't wait for a
convenient quarter. Find yours.

Thirty minutes. One process. A straight answer on what it's costing you and what a system could recover. Evening and Saturday slots — because we know when a plant head is actually free.

No pitch · No slides · Phone call, not a video link