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Until now. HOP makes human excellence scalable.
Over 60% of manufacturing problems are still human-related. Manual operations and method—remains the hardest to scale.
The Last Unsolved Manufacturing Problem
Problem Statement
When scale up or launch a new line, failures almost always trace back to people and processes.
✗ New operators lack instinctive expertise
✗ Supervisors miss golden line judgment
✗ Engineers can’t replicate IE expertise
✗ Tribal knowledge leaves with veterans
✗ SOPs don’t reflect reality
✗ Training takes too long, varies wildly
✗ Quality issues from unmeasured soft skills
Bold Statement
HOP is the first platform designed to capture, standardize, and scale human operational excellence—the “Man” and “Method” of 4M1E.
Three Layers. One Complete System.
HOP isn’t just a software. It’s a complete architectural approach to making human excellence repeatable. Every layer is designed to work together.
The Foundation Layer: Industrial-Grade Infrastructure
Everything great manufacturing systems need to work reliably at scale.
Integration & API Gateway
Seamlessly connects HOP with your existing MES, ERP, IoT sensors, and quality systems. Open API means HOP fits into your ecosystem, not the other way around.
Central Data Repository
Single source of truth for all production knowledge. Every work step, cycle time, defect, and solution stored securely and accessible instantly.
Security & Access Control
On premise computing and enterprise-grade security with role-based access. Your golden line knowledge is protected with the highest standards.
Edge Computing
Real-time AI processing at the edge. No cloud dependency means faster response and complete data sovereignty.
Production Dashboard
Unified view across all lines and locations. Compare performance against your golden standard in real-time.
Production Replay
Rewind production to any moment to see exactly what happened—invaluable for training and troubleshooting.
Operator Station & Digital Work Instructions
The frontline interface where operators interact with HOP. Always-current instructions and real-time guidance at every station.
The Intelligence Layer: AI That Learns Your Excellence
HOP becomes your golden line expert. Two forms of AI work together to capture both visible operations and invisible expertise.
Visual Intelligence
AI sees what your best people DO.
Watches, learns, and understands manual operations through AI vision.
Expert Intelligence
Expert Intelligence knows what your best people KNOW.
Captures, understands, and deploys the tribal knowledge and expertise that lives in documents, conversations, and experience.
The Modules Layer: Purpose-Built Tools That Solve Real Problems
Modules turn raw capabilities of Visual Intelligence and Expert Intelligence into focused solutions for all scaling challenges.
PREVENT - Zero Defects
What It Does
Catches quality issues before they happen by guiding operators to golden line standards in real-time.
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Key Functions
Operator Station: Visual step-by-step guidance displays golden line instructions with reference images at each workstation.
Work Step Verification: AI validates each step in real-time, instantly alerting when deviations occur before defects propagate downstream.
The Pain It Solves
New lines suffer from 2x-3x defect rates because operators lack the muscle memory of your golden line team. PREVENT eliminates this quality gap.
Provides forensic-level visibility into production history for instant root cause analysis.
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Key Functions
Production Analysis: Central repository captures every work step, action, component, and timestamp—revealing patterns invisible to traditional systems.
Production Replay: Frame-by-frame visual reconstruction shows exactly what happened at any production moment, pinpointing where issues originated.
The Pain It Solves
When defects appear downstream, you waste days trying to figure out what went wrong. TRACE gives you the answer in minutes.
Identifies bottlenecks and inefficiencies that keep new lines from matching golden line throughput.
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Key Functions
Production Analysis: AI detects anomalies in cycle times, material flow, and efficiency—quantifying exactly where lines diverge from golden performance.
Guided Improvement: Compares workstations against golden benchmarks, prioritizes opportunities by ROI, provides specific gap-closing recommendations.
Cycle Time Collection: Automatic timing data at each workstation builds complete picture of where time is lost across production runs.
Expert Assist: Manufacturing experts interpret data, validate root causes, provide proven solutions from similar production environments.
The Pain It Solves
Your copied lines never quite match the original. IMPROVE finds the hidden constraints and gives your engineers the answers, not just data.
HOP joins your production as early and as easily as possible. With a modular architecture built for land-and-expand, you can:
Land Early: Deploy HOP with granular architecture—no additional servers required. Start small and prove value on a single line before expanding
Scale Strategically: Expand at your pace. HOP offers complete flexibility as you grow across lines and locations, with token-based pricing that charges only as you use
Integrate Seamlessly: Open APIs connect to your existing tech stack
Customize Effortlessly: Vision Logic Blocks and configurable workflows adapt to your specific processes
Why HOP?
HOP vs. Others
WHAT OTHERS OFFER
WHAT HOP DELIVERS
MES Systems: Report what happened (after the fact)
Real-time Prevention + Historical Analysis Catch problems as they happen, understand why they happened
Static SOPs: Documents that operators ignore
Living Knowledge Base Documentation that adapts and deploys automatically
Training Programs: Slow, expensive, inconsistent results
Continuous Learning System Every operator learns from every expert's experience
AOI Systems: See problems, but don't understand context
Contextual Intelligence AI that understands your specific processes and history
Consultants: Leave, taking knowledge with them
Permanent Expertise Organizational knowledge that never leaves
HOP Delivers Value Across Your Organization
For Global Management
Scale your operations without losing productivity
When your best line can't be replicated, expansion becomes a profit drain. Resources get trapped in underperforming facilities, productivity drops across locations, and losses multiply globally. Stop letting failed scale-up cost you millions.
Golden line performance without golden line experience
Manage new lines to the same standard as your best line. HOP gives you the visibility, alerts, and guidance to maintain excellence even with newer teams.
PowerArena HOP has already delivered impressive ROI in factories similar to yours. From automotive to electronics, manufacturers are scaling their golden lines faster and more predictably.
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