Industry 4.0
Smart Factories
Transforming fragmented shop-floor operations into connected, data-driven manufacturing environments.
The Context
A mid-to-large manufacturing organization operated multiple production lines with limited real-time visibility into machine health, downtime causes, and throughput variability.
Critical production data existed across PLCs, SCADA systems, and maintenance logs but was siloed and reactive. Unplanned downtime resulted in lost production hours and high maintenance overhead.
The Friction Point
No real-time visibility into machine health or failure indicators. Maintenance activities were reactive and high false alarms created alert fatigue.
High false alarms created alert fatigue for operations teams.
Maintenance activities were reactive and calendar-based.
Spare parts planning lacked data-driven forecasting.
Predictive Maintenance Foundation
IoT Sensor Instrumentation
Retrofitted legacy equipment with vibration, temperature, and load monitoring sensors to capture machine heartbeats.
Edge-Level Data Processing
Deployed local gateway algorithms to analyze high-frequency data in real-time to reduce latency and bandwidth dependency.
Predictive Trend Analysis
Implemented centralized ingestion and threshold modeling to detect failure patterns and integrate with CMMS systems.
Impact on OEE
Unplanned outages.
Improved response.
Reduction in overstock.
Asset uptime increase.
Digital Twin Simulation
Why build physical prototypes when you can simulate perfection? We built a full digital replica of a factory floor to optimize workflows before a single brick was laid.
Digital Engineering
& Simulation
Simulating production realities to optimize throughput before physical execution.
The Challenge
A manufacturing engineering team faced high costs and delays during line reconfiguration, equipment layout changes, and commissioning of new production workflows.
Physical prototyping was expensive, time-consuming, and carried safety risks. Design decisions lacked predictive validation before implementation on the shop floor.
Long commissioning cycles for new production lines.
High dependency on physical prototypes.
Limited ability to test failure scenarios safely.
Operator training only possible after deployment.
The Solution: Digital Twin Simulation Platform
We developed a physics-based 3D digital twin of production lines for simulation of throughput, bottlenecks, and material flow, enabling scenario testing for layout changes.
Rigorous 3D simulation of production physics.
Identifying bottlenecks before execution.
Virtual training using real process data.