REAL PILOT OUTPUT — ANONYMIZED

What You Receive

Every Model T engagement produces three key documents: a product concept with architecture and BOM, meeting preparation notes, and a mini-offer deck.

Below are real documents from a pilot engagement with a professional imaging equipment manufacturer. Client identity, stakeholder name, concept names, and all identifying details have been anonymized.

01

Product Concept Document

Code: MT-PC-007 · Industry: Industrial Monitoring & Control · Target FPGA: CertusPro-NX (Lattice)

Executive Summary

Edge-computing predictive maintenance module for industrial rotating equipment. Combines vibration analysis, thermal profiling, and power-quality monitoring in a single ruggedized unit — replacing 3 separate sensor systems with one integrated solution. FPGA-based signal processing enables real-time anomaly detection at the edge without cloud dependency.

Context & Market Gap

Industrial facilities spend $50B+ annually on unplanned downtime. Current monitoring solutions require cloud connectivity, multiple sensor vendors, and specialized integration. The market lacks an all-in-one edge device that combines sensing, processing, and actionable output.

No existing product combines vibration + thermal + power-quality monitoring with on-device ML inference in a DIN-rail form factor under €800 BOM cost.
— Unplanned downtime costs industrial plants $20K–$250K per hour depending on sector
— Existing solutions require 3–5 separate sensor systems + cloud gateway + subscription
— Plant operators want actionable alerts, not raw data dashboards
— Regulatory push (EU Machinery Regulation 2027) demands predictive safety capabilities
— Target customer: mid-size manufacturing plants, 50–500 monitored assets
Solution — Before vs After

Integrated edge-AI monitoring module with three sensing modalities, FPGA-based real-time processing, and local decision engine. Outputs actionable maintenance recommendations directly to plant SCADA/MES without cloud dependency. Optional cloud sync for fleet-level analytics.

Dimension
Before
After
Sensor systems
3–5 separate devices, different vendors
1 integrated module, single vendor
Data processing
Cloud-dependent, 5–30 min latency
Edge processing, <500ms to alert
Installation time
4–8 hours per monitoring point
<45 minutes per monitoring point
Annual cost per point
€2,400–€4,000 (hardware + subscriptions)
€800 one-time + €120/year optional cloud
Anomaly detection
Threshold-based, high false-positive rate
ML-based pattern recognition, <2% false positives
Integration effort
Custom per-site, weeks of setup
Plug-and-learn, auto-baseline in 72 hours
High-Level Architecture

Four-layer architecture: Sense → Process → Decide → Act. All layers operate independently of cloud connectivity. FPGA handles real-time signal conditioning and feature extraction; MCU runs ML inference and business logic; communication module handles SCADA/MQTT/OPC-UA output.

Sensing Layer
3-axis MEMS accelerometer (±16g, 6.4kHz), IR thermal array (8×8, 60Hz), 3-phase power analyzer (0.5% accuracy)
Processing Layer
Lattice CertusPro-NX FPGA — FFT, envelope analysis, thermal gradient computation, power quality metrics at wire speed
Intelligence Layer
ARM Cortex-M7 MCU — TinyML inference engine, anomaly classification, remaining useful life estimation, adaptive baseline
Communication Layer
Industrial Ethernet (PROFINET/EtherNet-IP), MQTT, OPC-UA, Modbus TCP. Local web dashboard. Optional 4G/LTE uplink
Bill of Materials (Budget Estimate)

Budget-grade BOM for 1K-unit production run. Costs decrease 15–25% at 10K+ volumes.

Category
Component
Role
Budget
FPGA
Lattice CertusPro-NX (LIFCL-40)
Real-time signal processing & feature extraction
€85
MCU
STM32H7 series
ML inference, protocol handling, system management
€12
Vibration sensor
ADXL356 (3-axis MEMS)
Wideband acceleration measurement
€28
Thermal array
MLX90640 (32×24 IR)
Non-contact thermal profiling
€45
Power analyzer
ADE9153A
3-phase power quality monitoring
€8
Connectivity
W5500 + SIM7600
Industrial Ethernet + optional LTE
€22
Power supply
Wide-input DC-DC (9–36V)
Industrial power input with isolation
€15
Enclosure
DIN-rail, IP65, aluminum
Ruggedized industrial housing
€35
PCB + passives
6-layer HDI, impedance-controlled
Signal integrity for high-speed ADC paths
€40
Assembly + test
SMT + ICT + functional test
Production assembly and quality
€55
Total: ~€345 per unit @ 1K volume
Business Case
Market size

Predictive maintenance market: $6.9B (2024) → $28.2B (2030), 26% CAGR. Edge-based segment growing at 34% CAGR as enterprises reduce cloud dependency.

Revenue model

Hardware sale (€1,200–€1,800 per unit) + optional SaaS tier (€10/device/month for fleet analytics). Target: 60% gross margin on hardware, 85% on SaaS.

— Break-even: 800 units in Year 1 at €1,500 ASP
— Serviceable addressable market: ~120K mid-size industrial plants in EU+NA
— Customer ROI: payback in 4–8 months from avoided downtime
— Competitive moat: integrated sensing + edge FPGA processing — 18-month replication barrier
— Channel opportunity: white-label for industrial automation distributors (Avnet, RS, Farnell)
Implementation Roadmap
Phase 1 — Proof of Concept8 weeks
— FPGA signal processing pipeline validated on eval board
— ML model trained on open-source bearing fault dataset (CWRU)
— Sensor fusion algorithm — vibration + thermal correlation
— Functional demo: detect 3 fault types with >90% accuracy
Phase 2 — Engineering Prototype12 weeks
— Custom PCB design (6-layer, DIN-rail form factor)
— Industrial communication stack (PROFINET + OPC-UA)
— Auto-baseline algorithm — self-calibration in 72 hours
— Local web dashboard for configuration and monitoring
Phase 3 — Pilot Deployment8 weeks
— 10-unit pilot at 2 industrial sites
— Field validation: false-positive rate, detection accuracy, reliability
— Integration testing with customer SCADA/MES systems
— Certification pre-assessment (CE, IEC 61131-2)
Phase 4 — Production Readiness10 weeks
— DFM optimization, test jig development
— Certification completion (CE, IEC 61131-2, optional ATEX)
— Manufacturing documentation, BOM finalization
— Sales collateral, technical datasheets, application notes
Stakeholder Value Mapping
Plant Manager
Reduce unplanned downtime by 40–60%. Avoid catastrophic equipment failures. Clear ROI within 6 months.
Maintenance Engineer
Actionable alerts instead of raw data. Prioritized maintenance schedule. Mobile notifications with fault diagnosis.
CFO / Procurement
Replace 3 vendor contracts with 1. Predictable maintenance spend. CapEx-friendly hardware model with optional OpEx tier.
IT / OT Manager
No cloud dependency for core function. Standard industrial protocols. Fits existing network architecture.
VP Engineering (OEM)
White-label opportunity. Embed into own equipment portfolio. Differentiate with built-in predictive capability.
Key Risks & Mitigations
ML model accuracy insufficient on real-world data
→ Phase 1 validation on both synthetic and field-recorded datasets. Adaptive baseline reduces domain shift.
BOM cost exceeds target at low volumes
→ Modular design: base unit (vibration only, €180) + expansion modules. Volume pricing agreements with Lattice/ST.
Industrial certification delays
→ Pre-assessment in Phase 2. Engage notified body early. Design for compliance from day 1 (isolation, EMC, temperature range).
Customer SCADA integration complexity
→ Support 4 standard protocols. Pre-built connectors for top 5 SCADA platforms. On-site integration support in pilot phase.
02

Meeting Preparation Notes

Present two product concepts and discuss pilot engagement. Industry: Professional Imaging Equipment. Stakeholder: VP of R&D.

1. Company Context

Premium professional imaging equipment manufacturer. Industry leader with strong brand heritage and engineering excellence.

— Market leader in professional imaging — premium positioning, strong brand loyalty
— Mid-size enterprise, ~1,500 employees globally
— Core strengths: image quality, engineering precision, product reliability
— Current challenge: revenue stagnation, margin pressure from market shifts
— Key gap: limited AI/ML capabilities, no cloud-native solutions, no recurring revenue model
— Risk: losing market share in fast-growing automation segments
2. Stakeholder Profile — How to approach
VP of R&D
Type
Process-oriented leader, academic background in management
Values
Structured frameworks, measurable metrics, managed risk through staged approach
Style
Methodical — processes over technologies. Prefers governance models with clear milestones
Selling approach
— Lead with processes and metrics, not technology features
— Present ready collaboration frameworks with governance
— Show understanding of organizational challenges (R&D coordination)
— Avoid "technology jazz" without business context
Concept A — Primary
The Hook
"We studied your situation and noticed a gap: [Client] makes the best hardware in the world, but end users lose efficiency through manual operations. No premium vendor combines your quality with autonomous AI control."
Problem & Vision
"Today operators depend on manual processes — fatigue, errors, cost. [Client] risks losing share in growing automation segments. But imagine a system where [Client] products operate autonomously, coordinate with each other, and generate monthly recurring revenue for software and analytics."
Solution
"An edge-AI and robotics system integrated with your products. Autonomous operation, multi-unit coordination, cloud analytics, human override. Not just automation — a complete intelligent layer for your entire product line."
Proof
"We've built: autonomous robotics with real-time control (<100ms latency), automotive vision systems with safety certification (ISO 26262). Structured processes for AI integration with premium equipment."
Proposal
"6-month pilot. Hardware + AI + integration. Target: >95% accuracy, MVP readiness, confirmed references. Staged approach with managed risk through clear milestones."
Concept B — Secondary
Context
"In the era of synthetic media, 'seeing is believing' has disappeared. Professional users cannot trust digital files without cryptographic proof of authenticity."
Solution
"A hardware verification module integrated into your products. Cryptographically signs every output from source. Any post-processing modification breaks the digital signature — instant automatic verification."
Value
"Brand protection as the industry trust standard. Entry into verification-sensitive markets — legal, archival, news. New monetization through verification certificates. First-mover advantage — no premium vendor has made this a standard yet."
Objection Handling
"This is too risky — we're not ready for such changes"
→ Staged approach: PoC → Pilot → Scale. Managed risk with clear milestones. Start small — 6-month pilot, limited scope.
"We don't have internal resources for integration"
→ Engineering-as-a-Service: we handle integration, you get a ready solution without diverting core R&D resources.
"How will this affect our existing processes?"
→ Ready collaboration frameworks. Incremental integration into existing workflows. No disruptive changes — structured approach with traceability.
Closing question
"How does this align with your plans for R&D acceleration and transition to recurring revenue?"
03

Mini-Offer Deck

7-slide presentation prepared for the first meeting. Actual deck includes client-specific visuals and architecture diagrams.

01Title & Agenda
— Tailored title: "[Client]: [Solution Domain] & [Value Platform]"
— Subtitle: "Prepared specifically for [Client]"
— Agenda: Context → Concept A → Concept B → Next Steps
02Context — The "Why"
Professional operations are still tied to manual labor
— Operators depend on manual processes — fatigue and errors
— [Client] risks losing share in growing automation segments
— No premium vendor combines [Client]-grade quality with AI
— Vision: autonomous products + recurring revenue model
03Concept A — Solution
AI Automation System
— Edge AI core: >95% accuracy, <100ms latency
— Native integration with [Client] product ecosystem
— Multi-unit orchestration with intelligent handoff
— Cloud control & analytics: SaaS model
One-time sales → subscription. Margin growth + ecosystem protection.
04Concept A — Proof
— Architecture: Edge AI → Control → [Client] API → Cloud
— Reference: autonomous robotics, real-time navigation
— Reference: automotive vision, ISO 26262 certified
— Proven integration with premium equipment
05Concept B — Expansion
Verification Platform
— Trust crisis in the era of synthetic media
— Hardware cryptographic module in [Client] products
— Signs every output — any modification breaks the chain
Brand protection, new markets, certificate monetization.
06Concept B — Details
— Architecture: Sensor → Processing → Verification → Signed Output
— Synergy: both concepts strengthen [Client] ecosystem
— Concept B protects content created with Concept A
07Next Steps
Start small, scale with confidence
— 6-month Concept A pilot on limited scope
— Discuss Concept B expansion after successful pilot
— Technical workshop with structured collaboration framework