Peerox digitizes experience knowledge and make it usable for everyone with the self-learning assistance system for machine operators, MADDOX. The company’s mission is to support the exchange among colleagues (peers), to document experiential knowledge (operator experience) and to make it automatically retrievable according to the situation. This doesn’t only achieve a new level of production efficiency. With MADDOX, companies can also make better use of the great potential of their employees and arm themselves against employee turnover and demographic change. The vision of a working world characterized by continuous training and appreciation drives not only Peerox’s product development, but the entire company.
Interview with Hamza Ahmed, Marketing Team at Peerox GmbH.
How do your products or solutions help clients lower their overall operating costs?
Hamza Ahmed: Our production optimization software MADDOX helps manufacturing companies significantly reduce their operating costs by minimizing both the frequency and duration of machine downtimes, whether they’re short interruptions or longer ones that need interventions from the technical team. By implementing AI powered digital knowledge management in production, MADDOX makes practical knowledge from past issues instantly available to operators, enabling faster problem-solving and preventing recurring errors. This approach helps companies improve their Overall Equipment Effectiveness (OEE), stabilize production, and achieve measurable cost savings over time.
In what ways do you contribute to improving efficiency or productivity for your clients?
H.A: MADDOX improves productivity and efficiency in two direct, measurable ways.
First, it lowers the cost per unit by helping to reduce machine downtime — both how often machines stop and how long they stay down — so you produce the same output for less money. Second, it increases throughput by enabling teams to fix problems faster and avoid repeat incidents, so you can produce more within the same production time and therefore grow profit margins without increasing fixed costs.
On top of that, MADDOX gives production managers real flexibility: in slow seasons they can switch focus to cost-saving and stability (fewer expensive interventions), and in peak demand periods they can push for maximum output with confidence because operational know-how is available at the operator’s fingertips. That dual capability — reduce cost per product _and_ scale output when needed — is where the biggest business impact comes from.
How do you help clients reduce energy, material, or resource consumption?
H.A: MADDOX reduces resource consumption by stabilizing production processes and preventing avoidable machine stops. Each unplanned interruption generates waste — from scrap materials to inefficient energy spikes during restarts. By enabling operators to resolve issues quickly and avoid repeat problems, MADDOX keeps machines running under optimal conditions.
Best-practice knowledge cards also ensure correct machine settings, reducing scrap caused by incorrect configurations and lowering the energy required per good unit produced. The result: fewer restarts, less scrap, and significantly more resource-efficient production.
What technical characteristics in your solutions reduce maintenance or lifecycle costs?
H.A: MADDOX empowers machine operators by giving them direct access to practical troubleshooting knowledge through digital knowledge management in production. This means they no longer need to constantly interrupt experienced workers for guidance, saving valuable expert time. As a result, experienced staff can focus on optimization projects and other high-value tasks, rather than putting out fires. By enabling operators to resolve issues independently, we help reduce machine downtime, which not only reduces maintenance effort and costs over the machine’s lifecycle but also improves overall operational efficiency.
How do you support clients in minimizing downtime or production interruptions?
H.A: We make the right knowledge available exactly when and to whom it’s needed. Operators can access the most relevant information for a specific issue directly — without searching or waiting for help. This immediate guidance speeds up problem-solving, reduces the frequency and duration of machine stoppages, and keeps production running smoothly.
In what ways do your solutions simplify processes and reduce further costs?
H.A: Traditionally, operators had to search through large notebooks or manuals to find solutions, which required quick problem analysis and familiarity with technical terms. This was time-consuming and often meant asking colleagues for help, which delayed both troubleshooting and their colleagues’ work.
MADDOX simplifies this process by delivering recommended solutions instantly, tailored to the specific error as it occurs. This not only speeds up recovery but also reduces labor costs and prevents further delays in production.
How do your technologies enable clients to scale operations in a cost-effective way?
H.A: MADDOX enables clients to scale operations cost-effectively by transforming the way knowledge is captured and shared. With all practical know-how documented and instantly accessible through digital knowledge management in production, new employees can become productive much faster, and onboarding processes become efficient and consistent.
This is especially valuable during expansions or when opening new factories, as companies can scale production without proportionally increasing training time or relying heavily on experienced staff, keeping costs under control while maintaining operational quality.
How do you help clients meet regulatory or sustainability requirements without excessive costs?
H.A: MADDOX helps clients meet them efficiently by embedding compliance guidance directly into the workflow. For example, with regulations like the EU’s new packaging and packaging waste regulation, operators need to configure machines precisely in compliance. Our software enables the creation of detailed knowledge cards — including images and videos — at the exact moment of operation, ensuring machines are set correctly and remain compliant.
This reduces errors, minimizes downtime, and avoids the high costs associated with non-compliance or manual oversight.
What role does automation or digitalization play in cost savings for your clients?
H.A: In the context of knowledge management, digitalization is more than an optimization — it’s a critical turning point. With demographic shifts and experienced workers retiring, valuable operational know-how is at risk of being lost.
Our production optimization software MADDOX captures and organizes this knowledge digitally, making it instantly accessible to operators. This ensures continuity, reduces reliance on scarce experts, prevents costly mistakes, and helps reduce machine downtime by enabling faster problem resolution even as experienced staff transition out. This ultimately leads to significant savings in both time and operating costs.
Can you share a concrete example where your solutions generated measurable budget savings?
H.A: As mentioned earlier, MADDOX generates measurable cost savings by improving Overall Equipment Effectiveness (OEE). The core mechanism is straightforward: operators can access proven solutions instantly when issues arise through our AI powered digital knowledge management in production solution. This capability helps reduce machine downtime in two ways — fewer stops occur because operators can prevent recurring problems, and when stoppages do happen, they’re resolved faster without waiting for expert intervention.
The cumulative effect on OEE translates directly to lower cost per unit and higher throughput, delivering tangible budget savings that our clients can track and measure over time. An example of that is: Best Practice in the Pharmaceuticals Industry: How AI-Driven Knowledge Management from Peerox Increased OEE by 7%
