Every line. Every shift.
Checked by AI.
Zigzag AI turns the CCTV your plant already has into a supervisor for every line and every shift. Skipped steps, stopped machines and safety risks reach the right person on WhatsApp while there is still time to fix them.
- No new hardware
- Live in 2 hours
- Fully customisable
CAM 29 · Battery room
CAM 07 · CNC bay
CAM 35 · Mixing station
CAM 28 · Frame welding line
CAM 33 · Forge shop
CAM 32 · Loom shed
CAM 04 · Staff gate
CAM 19 · Stores
CAM 24 · FG warehouseTrusted by manufacturers across India
One missed step. Here's what it really costs.
A story many plant heads have lived through. The figures are an example.
- 1
A step gets skipped
The gasket is not placed at station 3. Nobody is watching the line at that hour, and the register still gets signed.
Line 2 · SOP registerGasket placed before coverBolts torquedNight shift · Signed - 2
The lot is rejected
The customer's incoming check finds the missing gasket. All 1,240 parts come back, with a debit note and the freight on you.
+ ₹2.6 lakh
Customer quality noticeLot 2417 rejected
Gasket missing in sampled parts.Returned1,240 pcsDebit note₹40,000 - 3
Rework costs almost as much as making them again
Every part is stripped, checked and refitted. Two days of line time are taken from this week's orders, so another dispatch slips.
+ ₹1.9 lakhMaking 1,240 new₹2.2 lakhReworking them₹1.9 lakhAnd 2 days of line time - 4
Your name takes the hit
Your supplier rating drops. A surprise audit is booked. The next order goes on hold until you show what changed.
+ the next orderSupplier ratingABProcess auditBookedNext orderOn hold - 5
And nobody can say why
Which shift? Which station? Who? The register says done, and there is no proof either way.
Which shift?Which station?No proof either way
And it isn't only quality
Now imagine your night supervisor knew at 02:41 AM.
Meet your AI supervisor
Zigzag AI turns the CCTV you already have into a supervisor that watches every line, every shift, and tells the right person the moment something goes wrong.
Sees it as it happens
Every step, machine and person your cameras can see, checked against your own rules, around the clock.
Tells the right person
A WhatsApp alert with the clip goes to the supervisor in seconds. If nobody acts, it escalates.
Proves it was fixed
Every alert is tracked to closure with a photo, ready for customer audits and your review.
Quality first
- Every SOP step checked
- Defects caught before dispatch
- Proof for every customer audit
Production and machines
- Output counted against target
- Stops and idle machines in minutes
- Cycle time for every stage
Safety and security
- PPE, forklifts and cranes
- Smoke, fire and spills
- Perimeter, gate and material
If your camera can see it on the floor, Zigzag AI can check it.
Pick an area to see the checks plants run every day.
Quality and SOP
Every step done, in the right order, at every station. Skipped checks and defects are caught on the line, not at your customer's gate.
Rules people write
Try writing your own
Also checked in this area
- Every SOP step, in the right order
- First-piece and in-process checks done on time
- Visible defects: scratches, dents, holes, stains
- Line clearance at every batch change
- Chemicals added in the right order and time
- Leak and pressure tests run for the full time
- Earthing before solvent transfer
- Fabric, coating and print faults on textile lines
Production and counting
What you really made, hour by hour, and where the line slowed down. Counted on camera, not filled in at shift end.
Rules people write
Try writing your own
Also checked in this area
- Output per hour against target
- Parts, cartons, rolls and bags counted
- Cycle time per stage and per shift
- Changeover and roll change time
- Bottlenecks and work piling up
- Material waiting between stages
- Empty hooks or gaps on the conveyor
- Parts dropped on the floor
Machines and downtime
Every stop, every idle minute and every machine running without its operator, with the time and how long it lasted.
Rules people write
Try writing your own
Also checked in this area
- Downtime per machine, with duration
- Idle and unmanned machines
- Error and warning lights on the machine
- Maintenance time on each machine
- Availability figures for your OEE
- Hopper or feeder empty, line waiting
Safety and PPE
Helmets, gloves, forklifts, cranes, fire and spills. The seconds that matter go to the person who can act.
Rules people write
Try writing your own
Also checked in this area
- Helmets, gloves, goggles and safety shoes
- Forklifts too fast or in walkways
- People under crane loads
- Oil spills and leaks on the floor
- Overheating machines and early smoke
- Machine guards open while running
- Smoking in no-smoking areas
- Unsafe lifting and posture
People and HR
Who is on the floor, where the shift's time goes, and how people are treated. Conduct alerts go only to HR, with the clip.
Rules people write
Try writing your own
Also checked in this area
- Workplace conduct (POSH) alerts to HR
- Touching, grabbing or hugging without consent
- A person cornered or their exit blocked
- Headcount per area against the shift plan
- Contract workers billed against those present
- Late starts and early leaving at shift change
- Phone use, idle time and long breaks
- Active man-hours per station
5S and housekeeping
Walkways clear, tools in place, waste where it belongs. Checked against your schedule, not once a month.
Rules people write
Try writing your own
Also checked in this area
- Waste dumped outside marked areas
- Bins and racks overflowing
- Emergency exits and lanes kept clear
- Tools back on the board at shift end
- Forklift or crane ready when needed
- Cleaning rounds done on schedule
Perimeter and security
Walls, gates, yards and stores, watched every night without a break. Your guards act on alerts instead of doing more rounds.
Rules people write
Try writing your own
Also checked in this area
- Wall and fence crossing
- Scrap thrown over the wall
- Entry into stores or yard after hours
- Sleeping or missing guards
- Employee entry by face recognition
- Visitors logged and tracked inside
- Frisking done at the exit gate
- Doors left open past a set time
Gate, docks and material
Every truck, every carton and every pallet moved from store to dock. Your gate becomes a record you can search.
Rules people write
Try writing your own
Also checked in this area
- Number plates logged at entry and exit
- Truck waiting at the bay too long
- Loading outside the marked bay
- Turnaround time per truck
- Finished goods tracked from floor to dock
- Raw material from store to line
- Subcontractor material in and out
- Gate pass only after loading is confirmed
Have a check that is not listed?
Zigzag AI is not a fixed list of features. If a supervisor standing at your camera could notice it, we can most likely set it up as a check. Tell us what you need and our team will tell you how it would work at your site.
Checks plants have asked for
From the first shift to the morning summary
The alerts one plant gets in an ordinary day, and what happened next.
41 of 48 workers on the floor. Line 2 is 7 short.
Station 3: gasket not placed before the cover.
Die change on press 2 took 38 min against 25.
Line 2 is 60 units behind the 10 AM target.
Press brake idle 25 min, no operator.
Forklift within 2 ft of a worker in aisle B.
First-piece check done after the tool change.
Truck out with 240 cartons, matches the invoice.
Person in the scrap yard after hours.
From camera to action in four steps
Connect cameras
Any CCTV or NVR your plant already has.
Write a rule
In plain words. No code.
Get alerted
Real-time alert on WhatsApp or email.
Fix and close
Tracked to closure, escalated if missed.
Type a rule. See the alert your team would get.
This is how simple it is to set up a check. Pick an area of your plant, write what you want watched, and preview the alert.
Every plant is different. Your checks will be too.
Pick your kind of plant to see the checks teams like yours set up first.
Every line, every shift, one view
See your whole plant in 3D. Tap any area to see what is happening there.
Command Center
All plants · TodayCompliance trend
Plants by compliance
Alerts on a 3D map of your plant
Know exactly which line, bay or gate needs attention.
A summary every morning
What happened on every shift, what is open and who owns it.
Audit-ready reports
Every alert with its clip, owner and closure time, ready for customer and safety audits.
Every plant side by side
Rankings and trends across all your plants and lines.
One set of cameras. Answers for everyone in the plant.
Owner and MD
Worried about: Money leaking where you can't see it
- Idle time, rework and headcount in one view
- A plant summary on WhatsApp every morning
Plant head
Worried about: A night shift nobody sees
- Every line and shift checked the same way
- Plants ranked side by side
Production head
Worried about: Skipped steps and empty stations
- Alert while the part is still on the bench
- Utilisation per machine and shift
Quality head
Worried about: A rejection with no root cause
- Video proof of every SOP step
- Line clearance checked at each batch change
EHS and safety
Worried about: An accident on your watch
- PPE, forklifts and zones checked 24/7
- Smoke and spills flagged in seconds
Security and dispatch
Worried about: Material leaving without a record
- Every truck in and out with its number
- After-hours movement at the yard and gate
Maintenance head
Worried about: Breakdowns found too late
- Stopped and idle machines flagged in minutes
- Maintenance time logged per machine
HR and admin
Worried about: A conduct complaint with no proof
- Workplace conduct (POSH) alerts with the clip
- Headcount checked against contract bills
What Zigzag AI pays back in your plant
Start with the two biggest leaks in most plants, machine downtime and rework. Then add the rest, with your own numbers.
- Machine downtime
- Rework, rejections and returns
- Labour time and headcount
- Scrap, theft and incidents
An estimate from your inputs, at 26 working days a month and 8-hour shifts.
What plants typically see
A line loses 45 minutes a day to machine stops and operator delays
- Zigzag AI shows the exact cause and length of every stop
- The supervisor hears in minutes, not at shift end
- Lost machine time comes back without new machines or more people
What changes when your cameras start working for you
Once every step was checked on camera and missed steps reached the supervisor in real time.
Caught at the station
Missed steps reach the supervisor while the part can still be fixed, not after dispatch.
Idle time you can see
Real utilisation per machine and shift, instead of a number filled in at shift end.
Every alert has an owner
Each issue is assigned, tracked and escalated, so nothing falls between shifts.
Proof, not paperwork
Checklists backed by video, ready for customer audits and head office.
Additional hardware that closes the loop
Zigzag AI runs on the cameras you already have. Add these only where they help: to reach spots your CCTV misses, run everything on site, or put alerts where people work.
Zigzag AI Relay
A small box on your network that links your existing CCTV or NVR to Zigzag AI over an encrypted connection. Your team controls it fully.
- Any camera brand
- Encrypted transfer
- You control access
CAM 2902:14:37Smoke 96%Unsafe lifting at storesCAM 19 · StoresShutter open at 11:20 PMCAM 24 · FG warehouseGasket not placedCAM 11 · Line 2
Zigzag Alert
A touch screen for a line, station or control room. It puts the AI snapshot on screen and announces it out loud the moment your cameras spot a problem.
- 7 inch touch display
- Built-in speaker
- Acknowledge or replay on screen
Zigzag AI Cue
A compact alert speaker for any line, bay or gate. It calls out each alert so the nearest person can act, even without a phone.
- Loud, clear voice alerts
- Small status screen
- Set up from the app
Zigzag Camera
A portable camera that connects over Wi-Fi with no new wiring. Put it wherever your CCTV does not reach and start checking in minutes.
- No new wiring
- Place it anywhere
- Ready in minutes
Zigzag AI Drone
An autonomous drone that flies preset routes, checks what it sees, raises alerts, and returns to its charging dock. No pilot needed.
- Flies preset routes
- Alerts and acts live
- Self-charging dock
Zigzag AI GPU Server
A high-performance GPU server installed at your facility for on-premises deployment. Every camera is analysed on site, so footage never leaves your plant.
- Built for 50+ cameras
- Footage stays on site
- Works without internet
In the cloud or on your premises
The same Zigzag AI, two ways to run it. Pick what fits your plants, your scale and your data policy.
Cloud
Fastest way to start- Live in 2 hours on the cameras you already have
- Hosted on Zigzag AI servers in India, or on your own cloud account
- Encrypted end to end, and you control who sees what
- New checks and model updates arrive automatically
- Easy to scale: add cameras and plants anytime, no new setup
On-premises
Everything stays on your site- Runs on a Zigzag AI GPU Server installed at your plant
- Footage and data are stored only in your premises
- Nothing goes to the internet, with an air-gapped option
- Connects to your NVR, VMS and internal network
- Your IT team holds full control and access
Built in India. Your data stays in India.
Your plant footage is your business. Zigzag AI is designed, built and hosted in India, and certified to international standards.
Talk to our security teamBuilt entirely in India
Designed, developed and supported by our team in India.
Servers in Mumbai only
Every frame is processed and stored on servers in India. None outside.
No Chinese AI models
Our own models, built and trained in India for real Indian plants.
ISO/IEC 27001:2022
Certified information security management.
ISO/IEC 42001:2023
Certified management of AI systems.
On-premises option
Large plants can run Zigzag AI fully on their own servers.
See it work on your own plant first
Start with a free POC. We connect a few of your cameras, set up your checks and send real alerts to your team.
- Unlimited checks written in plain words
- Real-time alerts on WhatsApp or email, with clips and escalation
- 2D and 3D dashboards, daily and shift reports
- Setup, tuning and support by our team
Book a demo
Tell us where to reach you. We usually reply the same day.
Questions plant teams ask us most
Yes, in most plants. Zigzag AI works with the CCTV and NVRs you already have, from any major brand. We check every camera during the POC, and for spots your cameras miss you can add a Zigzag Camera.
Most plants go live within 2 hours. We connect your existing cameras, set up your first checks with your team, and start sending alerts.
Anything a supervisor standing at the camera could notice: SOP steps, PPE, machines running or idle, people at stations, forklifts, walkways, spills, smoke, trucks and gate movement. If it is not on our list, describe it and we will tell you how it would work.
The person you choose, on WhatsApp or email, with a snapshot or short clip, the camera and the time. If nobody acts, it escalates to the next person. Alerts can also show and play out loud on a Zigzag Alert at the line.
Most plants introduce it as a safety and quality tool. It watches steps, safety and machines, and alerts go to supervisors so problems are fixed on the spot.
Yes. One dashboard shows every plant, line and shift, with rankings, trends and a summary every morning.
Every check is tuned on your own cameras during the POC, and each alert carries the clip, so your team can confirm it in seconds and mark anything wrong. The checks improve with that feedback.
Yes. It counts parts, cartons, rolls, trucks and people, and checks them against your target, job card or invoice. Fast counting runs a quicker analysis on that camera, which we set up and test during the POC.
Yes. Counts, gate and vehicle logs, and alerts can flow into SAP or your ERP. Our team sets up the link with your IT team.
Plans start from ₹20K a month. Every engagement starts with a free POC on your own cameras, so you see it working before you pay.
Your cameras already see every line.
Put a brain behind them.
See Zigzag AI catch real issues on your own floor, free.