How We Work
“At Aitheon, we design and deploy agentic AI solutions that not only predict failures but act autonomously on your behalf. Our AI operators monitor, analyze, and intervene within safe boundaries—ensuring your systems run efficiently with minimal manual oversight. Our step-by-step deployment process ensures you move smoothly from passive monitoring to proactive, autonomous control, reducing downtime and optimizing performance.
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Initial Consultation and Assessment
Our process begins with a thorough on-site evaluation by our experienced specialists. We collaborate closely with your team to:
Evaluate your readiness for autonomous control — identify opportunities where AI agents can replace operator tasks safely
Identify critical assets, machinery, and equipment prone to failures
Evaluate current maintenance practices, data collection systems, and existing sensor installations
This assessment enables us to customize our solution to address your specific pain points and improve operational efficiency. We also establish baseline metrics and performance standards to precisely measure improvement over time
Customized Solution Design
Based on our findings, we design a predictive maintenance strategy tailored to your needs:
Sensor Selection and Placement: Choosing industrial-grade IoT sensors to monitor parameters like vibration, temperature, current, and airflow
Data Collection Infrastructure: Integrating gateways and wireless communication protocols to capture real-time equipment data
Maintenance Dashboard Configuration: Designing user-friendly interfaces for real-time monitoring and predictive insights
Agent Logic & Control Strategy: Define how the AI operator will make decisions, within guardrails and human override
Every element of the solution is crafted to provide actionable insights with minimal disruption to existing systems. Design choices are guided by Six Sigma practices to minimize process variation and ensure consistent reliability.
Professional Installation
Our process begins with a thorough on-site evaluation by our experienced specialists. We collaborate closely with your team to:
Equipment Preparation: Installing sensors on machines like CNCs, robots, laser systems, pumps, and HVAC units
Wiring and Connectivity: Integrating sensors with our IoT gateways for seamless data flow
Safety Compliance: Adhering to industry standards and safety regulations during the entire process
Validate control interfaces and safe actuation paths — ensure the AI operator can issue commands only within permitted limits
Our experts coordinate with your maintenance team to avoid operational downtime wherever possible.
Data Integration and System Configuration
Once hardware installation is complete, we:
Integrate Data Streams: Feed sensor data into our predictive maintenance platform
Baseline Establishment: Define normal operating conditions and performance thresholds. These thresholds then serve in Six Sigma Control mechanisms to detect deviations and maintain stable operations.
Alarm and Notification Setup: Configure alert systems for critical deviations
Establish fallback rules and safe thresholds (i.e. guardrails) for autonomous operation
This step transforms raw data into meaningful insights, setting the stage for AI-driven predictions.
AI/ML Model Development and Training
Our AI engineering team develops predictive models customized to your equipment’s behavior:
Model Calibration: Using historical data and real-time inputs to fine-tune machine learning algorithms
Dynamic Learning: Implementing models that continuously learn from new data to improve prediction accuracy
Hybrid Analytics: Combining data-driven insights with expert-defined rules for comprehensive fault detection
Develop agentic decision models — combining predictive models with control policies
Train the agent to act under safe constraints, simulating interventions before going live
The result is a system that anticipates issues before they become costly problems.
Continuous Monitoring and Predictive Analysis
With AI models in place, our system continuously tracks equipment performance:
Anomaly Detection: Identifying subtle changes in vibration patterns, temperature fluctuations, or current usage
Health Scores: Providing a health index for each piece of equipment, helping prioritize maintenance tasks. Through continuous analysis and control, we help clients maintain consistent performance and reduce unplanned variation.
Trend Analysis: Offering long-term insights into machine wear and potential future failures
The system can also autonomously trigger corrective actions (within safe limits) based on anomaly identification
Our technology empowers your team to shift from reactive to proactive maintenance strategies.
Ongoing Support and Optimization
We provide comprehensive support to ensure long-term success:
System Updates and Enhancements: Regular updates to AI models and software
User Training: Equipping your team with the knowledge to maximize system benefits
Remote and On-Site Assistance: Quick response to technical queries and maintenance challenges
We remain a trusted partner, continuously optimizing the system to adapt to changing operational needs.
Feedback and Continuous Improvement
We actively seek feedback to refine our solutions:
Performance Reviews: Analyzing system efficiency and predictive accuracy
Customer Insights: Incorporating user experiences to enhance functionality
Feature Customization: Adding new capabilities aligned with your evolving requirements
We apply Six Sigma’s continuous improvement mindset — always refining process steps, reducing defects or inefficiencies, and ensuring the system stays aligned with high reliability and cost efficiency.
Schedule a Demo — Agentic AI for Production
