Study Conducted by Startup Cogtive Reveals an Annual Waste of R$ 47 Billion in the Brazilian Automotive Industry
A new study launched by Cogtive, a Brazilian startup dedicated to developing technological solutions for the manufacturing industry, brings an alarming finding: the Brazilian automotive industry suffers an annual loss of R$ 47 billion, resulting from the neglect of its productive potential, a phenomenon known as “hidden capacity.”
This amount represents a considerable portion of Brazil’s total industrial losses, estimated at around R$ 500 billion per year. The figure is equivalent to a slice of 5% of the country’s Gross Domestic Product (GDP).
How Can Technology Uncover Hidden Capacity?
Cogtive, which utilizes artificial intelligence and the Internet of Things to optimize production processes in the industry, suggests that if this “hidden treasure” were properly utilized, productivity in the automotive sector could increase by up to 30%.
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While much of the industry rushes to automate production, Rolls-Royce takes over 600 hours to hand-build each car in Goodwood and still accepts orders so complex that they can take up to four years to be completed.
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Smaller than the Model Y, lighter, with a single motor and designed to cost less than the current Model 3, Tesla’s new compact electric SUV is born in China and could seal the automaker’s return to the race for mass-market electric vehicles.
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Kawasaki took the technology from its most brutal racing bikes, squeezed it into a 400cc 4-cylinder engine that revs to 15,000 RPM, and created the ZX-4R, a machine that shouldn’t exist in this displacement but is making experienced riders rethink everything they thought they knew about mid-range motorcycles.
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The culture of cars that jump on the asphalt was born in the garages of Mexicans in the 1940s, was treated as a crime in the United States for decades, and has now become an official postage stamp of the American Postal Service in a twist that no one expected.
The main causes of this hidden capacity include poor management of processes, unnecessary breaks on the production line, low asset performance, and inadequate allocation of labor. The solution, according to the startup, lies in adopting advanced technological resources, such as artificial intelligence and hyperautomation, in process management.
Hidden Capacity in Other Sectors
In addition to the automotive industry, Cogtive’s research indicates that other industrial segments also face significant financial losses due to hidden capacity. The food and beverage sector tops the ranking, with an estimated loss of R$ 276 billion, followed by the pharmaceutical industry (R$ 45 billion), personal hygiene, perfumery, and cosmetics (R$ 36 billion), and finally, the paint and varnish industry (R$ 3 billion).
Based in Cubo, São Paulo, Cogtive won the Pitch LTNtech in 2022, a renowned competition for early-stage Latin American startups held in Michigan, United States.

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