The Future of Manufacturing: AI and Smarter Process Improvements
Artificial intelligence is no longer experimental in manufacturing. It is quickly becoming a practical way for companies to strengthen decision-making, improve consistency, and reduce wasted effort. At Waukesha Metal Products (WMP), AI is being built into everyday processes to anticipate problems before they occur and to help teams operate with greater confidence.
Guiding AI at WMP
Zach Schwarze, Project Engineer at WMP, has played a leading role in shaping the company’s early AI direction. He started by collecting input from across departments to identify areas where automation and analysis would deliver the greatest impact. That process led to prototyping sessions, which set the stage for WMP’s first two AI initiatives: predictive press analysis and AI-enabled quoting.
His focus now centers on coding and data flow. Rather than abstract research, the work is aimed at creating tools that can be tested, refined, and eventually scaled into production.
Predictive Analysis on the Shop Floor
Manufacturers have long collected press data, but using it effectively has been a challenge. WMP’s new approach changes that. A custom AI model draws on real-time press information – rates, changeover times, and part counts – to identify patterns that signal potential issues.
When a press begins to slow or drift off target, the system highlights the problem immediately. Adjustments can be made before downtime cascades into missed deadlines or added costs.
The advantages are clear:
- Less unplanned downtime
- Higher throughput on each press
- Stable, repeatable processes that support consistent quality
For WMP’s customers, that translates into dependable delivery and reduced production risk.
Quoting with Greater Speed and Consistency
The same philosophy extends to the front end of new programs. In partnership with Microsoft, WMP created a prototype that uses AI to read part prints and extract critical details. It then generates a feasibility score based on the company’s history and lessons learned.
Instead of spending hours on manual review, WMP’s program management team can move more quickly through the quoting process. Customers receive faster responses, and the consistency of those responses improves with each iteration of the model.
Although the system remains in development, it is already showing the potential to reshape quoting from a bottleneck into a competitive advantage.
A Better Experience for Customers
Predictive analysis and quoting automation share a common purpose: stronger outcomes for customers. Production data is monitored in real time, which reduces the chance of unexpected downtime. Quoting is supported by a structured model, which eliminates unnecessary delays.
The result is measurable:
- Shorter lead times
- Greater confidence in pricing and schedules
- Fewer surprises during production
- Continuous improvement backed by accurate data
These benefits apply to every industry WMP supports, from automotive and aerospace to defense, energy storage, and industrial equipment.
People and Technology Working Together
AI is not replacing people at WMP. It is giving them sharper tools. Repetitive tasks shift to the system, leaving employees free to focus on creativity, collaboration, quality oversight, and problem-solving.
“Predictive analysis allows us to move beyond reactive problem-solving toward proactive process control,” Zach explains. “By analyzing data in real time, we can make more informed decisions and deliver greater reliability for our customers.”
WMP is still in the early stages, but the direction is set. Predictive analysis on the shop floor and AI-supported quoting are building momentum, and future applications will continue to strengthen performance across the company.
Takeaways
Manufacturing is moving into a new era, and AI is central to that shift. At Waukesha Metal Products, AI is a set of practical tools being applied to solve problems and improve efficiency. With leadership from experts like Zach Schwarze, WMP is building a smarter, faster, and more reliable way forward for our customers.
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