Invisible AI + RealSense Bring Real-Time Visibility to the Floor
The challenge
Despite decades of digitization, most factory-floor activity remains largely unobserved, with manufacturers struggling to answer basic questions in real time about where bottlenecks are forming, how closely real work matches standard work, and which deviations are compounding into safety or quality issues. Traditional tools offer partial and episodic insights that are fragmented, delayed, or theoretical, rarely translating into immediate action on the floor.
The solution
Invisible AI built a platform around edge AI camera devices integrating RealSense D455 depth cameras with Nvidia Jetson compute and onboard AI processing. These intelligent agents can be deployed throughout manufacturing environments without requiring wearables, sensors, or cloud streaming, providing real-time spatial understanding of factory operations across entire lines rather than isolated workstations.
The results
Invisible AI’s platform is used by leading manufacturers including Toyota and spans automotive, heavy equipment, and electronics industries. The system delivers immediate visual feedback to operators within seconds, enabling faster learning and behavior change, while providing factory leadership with complete visual context for coaching and continuous improvement.
Real-Time Visibility Across the Entire Factory Floor
Invisible AI transforms raw visual data into actionable insight by deploying hundreds of intelligent agent cameras across production lines. Each device integrates RealSense D455 depth cameras with onboard AI processing and up to 4TB of storage, functioning as self-contained units that don’t require cloud streaming or coding and can be installed in days, often between shifts.
3D Vision Solves What 2D Cameras Cannot
After initially experimenting with standard 2D RGB cameras, Invisible AI found they failed at scale due to occlusions, perspective distortion, and lack of spatial reference. RealSense provides stereoscopic depth perception with high-quality 3D depth accuracy, active IR dot projection for reliable performance in challenging lighting conditions, and a 10-cm stereo baseline supporting the 0.5 to 8 meter range typical of factory floors.
Beyond Monitoring: A Visual Execution Layer
What began as a tool for immediate return on investment has evolved into a new category: the Factory Operating System. With massive volumes of spatial-temporal data, Invisible AI is becoming the system of record for how factories actually function, enabling manufacturers to design and optimize processes using real data rather than theoretical assumptions throughout the entire workflow lifecycle.