Building operational excellence through machine learning

Although artificial intelligence is sometimes hailed as the industry of the future, practical applications of this technology can be messy, risky and costly. This presentation offers a unique, candid look at the process of developing an industrial vision system for palletization quality control from a grassroots AI proof-of-concept to a fully functional system. This session will walk participants through a concrete, real-life use case that replaced manual, error-prone and costly counting methods with a reliable, scalable AI-based solution. We will share how we selected this use case, and provide a practical framework for identifying high-impact opportunities for AI adoption within existing workflows.

An early internal prototype at Shaw Industries that used open-source tools for barcode reading and box identification evolved into a full-scale implementation in collaboration with Accella AI. The Shaw Industries team will describe how they chose the best use case, gained early traction with few resources and then scaled up to an AI-enabled solution that decreased labor variability, increased inventory accuracy and produced a tangible return on investment. While AI is often discussed in broad strokes, real-world success stories are still rare. This talk is for manufacturing professionals seeking actionable strategies, proven benefits and a deeper understanding of what it takes to build a foundation for operational excellence through smart, scalable technologies.

The four distinct stages of this case study include infrastructure integration, vendor collaboration, proof-of-concept and deployment. From labeling COCO datasets to negotiating cybersecurity, patching and OT/IT integration, each phase offers useful lessons.

You'll leave with a framework for spotting AI prospects in your own business, a list of the main organizational and technological problems and practical advice on what makes AI partnerships between manufacturers and vendors successful. This is the session for you if you're searching for scalable, tested methods to move AI from a trendy term to the mainstay.

Key learning objectives

1. How to navigate AI projects in four practical phases: Learn a clear roadmap from PoC to production that includes model prototyping, vendor engagement, infrastructure hurdles and deployment commissioning.
2. Driving operational excellence through smart automation: See how targeted AI applications can reduce errors, cut costs and improve process reliability on the shop floor.
3. What actually makes a “good” AI use case: See how box counting and barcode reading emerged as a low-risk, high-reward AI use case and use the same filters to identify opportunities in your facility.
4. Lessons in infrastructure, compliance and governance: Understand how cybersecurity, monthly pathing, Docker environments and PLC communication affect your AI deployment before you begin.
5. Partnership playbook on how to work with external AI vendors: Discover what worked (and didn’t) in cross-functional collaboration, from camera mounting and annotation formats to expectations management.
6. How to move beyond the pilot trap: Learn how to architect scalable AI systems that move from pilot to plant-wide success and build internal buy-in and technical readiness along the way.

Companies

Founded in 2019, Accella AI provides cutting-edge AI-enabled solutions for manufacturing companies that allow them to reduce cost, improve quality and better utilize existing personnel and equipment. The Accella AI platform empowers companies to quickly implement advanced AI-driven solutions — such as quality control, predictive maintenance and analytics, and simplified human-machine interfaces (HMI) — using their existing workforce. Accella AI’s solution lowers the barrier to AI adoption and shields companies from the complexities of model development and life cycle management. https://www.accella.ai/

Shaw Industries Group, Inc. is one of the world's largest carpet manufacturers with more than $6 billion in annual revenue and approximately 22,000 employees worldwide. It is headquartered in Dalton, Georgia, and is a wholly owned subsidiary of Berkshire Hathaway. https://shawinc.com/

Presenters

Jeff Gentry, BSME, MBA, is a seasoned engineering leader at Shaw Industries. With a robust background in mechanical engineering and business management, he excels in driving operational efficiency and innovation. Currently advancing his expertise through graduate studies, Gentry is passionate about AI, robotics and strategic organizational development. 

Uli Palli is the CEO and chief data scientist at Accella AI, specializing in AI-driven solutions for smart manufacturing. With over 25 years in high-tech and IT, Palli focuses on implementing AI for visual quality control and predictive maintenance, enhancing efficiency and innovation on the manufacturing shop floor.