Tackling Challenges, Embracing Opportunities, and Unlocking the Potential of AI in European Manufacturing
Introduction
In today’s fast-paced manufacturing landscape, the adoption of advanced technologies such as artificial intelligence and robotics has become a strategic need. For CASP, a software firm based in Athens, Greece, specializing in production planning, scheduling, and industrial digital solutions, integrating AI was a crucial step toward enhancing agility, efficiency, and adaptability.
Thanks to their collaboration with AI-MATTERS, TRYGONS was able to [deploy and validate an AI-based visual monitoring system, helping them streamline production and achieve measurable improvements in quality, speed, and waste reduction]. This is their story.
The Challenge
Every organization embarking on an AI transformation faces unique challenges. For TRYGONS, the main challenge was improving the accuracy and reliability of manual sandwich assembly tasks where mismatching and misalignments often led to costly rework and material waste. Additionally, they needed support in gaining access to specialized AI knowledge, testing solutions in a risk-free environment, and ensuring smooth integration into their existing workflows.
“Errors at this point can lead to misalignments that compromise product integrity, generate material waste, and require costly rework”, explains Evagoras Zervas, European Project Coordinator and Mechanical Engineer at TRYGONS.
The Solution
AI-MATTERS provided TRYGONS with the resources and expertise they needed to overcome these challenges. Through specialized guidance in AI solution development, access to a safe, non-disruptive testing environment, and close collaboration with experts throughout the process, the organization was able to [design, test, and validate an AI-driven solution to support operators and improve accuracy during one of the most error-prone stages of the composite manufacturing process.
“All development and testing were carried out in a structured environment under realistic conditions, without interfering with our ongoing production, something we couldn’t have realistically achieved on our own under normal operating conditions,” says Evagoras Zervas.
The Results
The collaboration between AI-MATTERS and TRYGONS delivered tangible outcomes. Some of the key results include:
- 20–25% reduction in production time for the sandwich assembly stage, achieved by minimizing operator delays and decision-making time.
- Around 10% reduction in rework, thanks to improved placement accuracy and early error detection.
- 5–10% decrease in material waste, as the system helped prevent mismatches and scrapped components.
“By offering real-time visual feedback and verifying their actions during the assembly process, the system significantly reduced mental workload, stress, and fear of making costly mistakes. Operators felt more supported and confident in their work, which further contributed to consistency and engagement on the shop floor,” adds Evagoras Zervas.
Looking Ahead
Working with AI-MATTERS has been a pivotal step for TRYGONS in their AI adoption journey. Moving forward, they plan to expand the use of AI-driven solutions across additional stages of the production line, with a focus on improving real-time decision-making, quality control, and process adaptability.
“AI-MATTERS helped us see AI not just as a future concept, but as a practical tool to improve everyday operations. It strengthened our confidence to keep investing in AI across the shop floor, “ concludes Evagoras Zervas.
Conclusion
TRYGONS’ story demonstrates the transformative potential of AI in European manufacturing. By addressing challenges head-on and leveraging the resources of AI-MATTERS, they’ve paved the way for a future of smarter, more efficient operations.
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