23 AI Pilots and No Results? You've Got a Problem
I was once given two tours at the same company, on the same day, and the distance between them is everything wrong with how industry is approaching AI.
The morning tour was the innovation lab: a converted mezzanine with startup furniture, a 3D printer, idea walls dense with sticky notes, and a curated energy the tour guide called an ecosystem. It had cost a defensible amount and won a design award. When I asked which of its projects had reached production in three years, the answer took a while: parts of one.
The afternoon tour had no name and no furniture concept. A development engineer, two process people, and a maintenance veteran had—inside the ordinary product process, with the ordinary budget—cut a flagship product’s variant costs by a third and packaged its condition data into a service two customers were already paying for. When I asked how, the engineer shrugged: “We ship something every 90 days. Shipping teaches you.”
Same company. One place performed innovation; the other produced it. Hold that picture, because industrial AI is running the morning tour at scale.
Industrial Intelligence vs. AI
So let me define the distinction this piece turns on. Artificial intelligence is a technology: math, powered by data, that you can now rent by the month, and so can your fiercest competitor.
Industrial intelligence is something you must build: the compound of machines that read the process, an organization that reads the machines and leadership that knows what all of it is for. AI is electricity—the same current, delivered to every factory at the same price. Industrial intelligence is the plant you build around it.
A century ago, the winners of the electric age were not the factories that bought the most current; they were the ones that redesigned the whole plant around what electricity made possible. It is happening again. That is why industrial intelligence is essential, while AI is only an amplifier: an amplifier raises the volume of whatever signal you feed it—intelligence or confusion, honest data or flattered numbers.
Climbing the Ladder, One Rung at a Time
The uncomfortable truth the vendors will not tell you: The technology is real—predictive quality that catches drift before it becomes scrap, maintenance models that read bearings better than any veteran’s palm, quoting engines that do in minutes what took six weeks—and the way most industrial companies are approaching it still guarantees disappointment. Because AI is the top rung of a ladder, and companies keep trying to skip the rungs beneath it: stabilize, optimize, automate, digitalize—and then, on data made honest by all of that, intelligence.
Machine learning on top of a plant with no lean backbone does not transform the plant. It automates the confusion. If your operational equipment effectiveness (OEE) number has been flattered to look good in reviews, AI will faithfully optimize the fiction.
I have taught this to executive rooms for years as a single sentence: Organizational intelligence comes before artificial intelligence. Not after. Not instead. Before. Artificial intelligence, it turns out, rewards organizations that were already intelligent.
Soft Skills Are the Hard Currency
Industrial intelligence—the compound, not the ingredient—has three working faces.
Market intelligence: sensing where value is migrating before the income statement admits it, the way the margin has already moved from the machine to the intelligence around the machine.
Operational intelligence: the floor’s thousand human sensors and their new silicon reinforcements, mining losses no Pareto workshop would find.
Innovation intelligence: a pipeline that knows what to build next, and what to bury with honor.
Nobody builds an edge from an ingredient everyone can buy, which is why the compound, and not the algorithms, is the durable edge. In our masterclasses, we write one equation on the wall: Value = AI + LI + EI — artificial intelligence plus leadership intelligence plus emotional intelligence. Live with it a while and you learn it behaves like a product, not a sum: brilliant models times absent judgment multiplies to zero, and judgment times a workforce that quietly routes around the new tools multiplies to zero from the other side.
The bitter joke of the AI era is that it makes the soft skills harder currency than the hard ones.
A Simple Test
Here is a test you can run before lunch. Count your AI pilots. Then count your AI systems in production with a named owner and a profit-and-loss line. The ratio is your buzz-to-reality index, and if it is worse than 3 to 1, you do not have a technology problem—you have a system problem, and one more pilot will not fix it.
I have stood in front of proud slides announcing 23 pilots. Production systems: zero. That is not transformation. That is a science fair.
So what does Monday look like? Pick two or three use cases tied to money—a named owner, a sized value, an adoption path into the line and a gate that kills, because a portfolio that cannot kill cannot focus. Three use cases taken to production beat 23 pilots: every time, in every industry I serve.
Put the operators and engineers who must trust these tools into the design from day one—people support what they help create, at machine speed. And train your board to ask three questions of any AI system it funds: what data trained this, where does it fail and how do we verify it? You cannot govern what you cannot read.
The companies doing this are not the ones with the biggest AI budgets. They are the ones whose data is honest, whose fundamentals are mastered and whose people are learning without shame —the ones who were fit when the technology arrived.
The last industrial revolution asked how strong your machines were. The next one asks how intelligent your company is. All of it, together.
About the Author
Yannick Schilly
Co-founder and CEO, Altix Consulting
Yannick Schilly is co-founder and CEO of Altix Consulting, a Cincinnati-based industrial consultancy, and a former global operations executive who built and led manufacturing across Germany, China, and the U.S. His new book is The Superfit Company: Why Industrial Winners Never Stop Transforming (ALTIX Press).
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