ZeroKey Launches OmniVisor AI for Smart Factory Operations
News, Technology - October 28, 2025
ZeroKey has introduced OmniVisor AI, an operations-focused platform built on the company's Quantum RTLS-one of the most accurate industrial real-time location systems. The goal is simple: turn high-density 3D location data into live decisions that improve throughput, yield, and cost per unit.
As Matthew Lowe, CEO & Founder of ZeroKey, put it, "Factories powered by Quantum RTLS generate thousands of highly contextual data points about the state of the factory-from material flows and assembly operations to the movement of high-value assets... OmniVisor AI removes that chokepoint... and delivers real-time, holistic intelligence that factors in the dynamic state of the factory."
What Operations Teams Get
- Live material flow and WIP visibility down to millimeters in 3D.
- Faster bottleneck detection and line balancing with actionable recommendations.
- Exception handling for missing parts, stalled stations, or asset misplacement.
- Asset utilization insights for tools, fixtures, and high-value equipment.
- Early detection of quality drift through location-context signals.
- Shorter time-to-decision for supervisors and process engineers on the floor.
How OmniVisor AI Works
OmniVisor AI sits on top of Quantum RTLS-the data layer capturing 3D location with millimeter-level precision. It uses reinforcement learning and large language models to analyze context at scale and suggest next-best actions in real time.
- Contextual data in: Material flow, assembly steps, and asset movement from Quantum RTLS.
- Inference out: Recommendations and alerts that reflect current line conditions.
- Agentic workflow: A suite of AI agents, AI-native tool calling, and Model Context Protocol (MCP) support to interface with your tools and data sources.
- Human-in-the-loop: Supervisors approve, override, or automate actions with clear traceability.
The result is a factory that learns from its physical state, predicts issues before they hit the schedule, and adapts operations as conditions change.
Why It Matters Now
ZeroKey's Quantum RTLS is already trusted by more than 10% of the Fortune Global 500 across automotive, aerospace, and advanced manufacturing. OmniVisor AI builds on that footprint by connecting contextual datasets to inference models, closing everyday information gaps on the shop floor.
It's a value-first approach: less dashboard surfing, more decisions made on time where they impact takt, OEE, and cost.
Practical Use Cases to Pilot
- Cycle time control: Flag stations trending long and suggest rebalancing or temporary workarounds.
- WIP caps by zone: Alert when buffers exceed limits and propose pull signals to restore flow.
- Kitting accuracy: Identify mis-sequenced kits before they reach the station.
- Tool and fixture availability: Prevent delays by tracking location and readiness in real time.
- Changeover readiness: Confirm parts, tools, and people are in place before switching.
KPIs to Watch
- Throughput per shift and per line
- Station-level cycle time variance
- WIP levels by zone and dwell time
- First-pass yield and rework rate
- Asset utilization and search time
- Unplanned downtime minutes and causes
Implementation Checklist
- Map your top constraint lines and high-value assets; confirm RTLS coverage.
- Define decision thresholds (e.g., cycle time variance, WIP caps, asset dwell).
- Start with one pilot cell; enable alerts and human-in-the-loop approvals.
- Integrate with your existing tools via AI-native tool calling and MCP where useful.
- Standardize how recommendations convert into actions on the floor.
- Expand stepwise-cell to line to plant-once KPI lift is consistent.
Context and Further Reading
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Bottom line: OmniVisor AI brings AI agents to the work cell, fed by precise 3D context from Quantum RTLS. For operations leaders, that means fewer blind spots, faster decisions, and measurable gains where it counts.
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