MANUFACTURING
AI on the Shop Floor Outcomes That Show Up in OEE.
Predictive maintenance, OEE visibility across multi-plant estates, MES/ERP modernisation, shop-floor Copilots, and quality vision delivered AI-native.
90 days
Multi-plant OEE live
25–40%
Unplanned downtime reduction
38%
Planner cycle-time cut
OT/IT
Safe-segmentation delivery
The Problem We Solve in Manufacturing
Most manufacturers sit on plant data they cannot use. Historians are full, ERP-MES integration is patchy, and OEE conversations still rely on spreadsheets emailed at 9 a.m. Our manufacturing practice fixes the platform, surfaces the metric, and ships the AI workflows that drive it.
Where AI Moves the Needle
OEE & Plant Cockpits
Live OEE visibility across every plant, with drilldown to line, shift, and equipment. Mobile-first cockpits for plant managers; rollup cockpits for the COO.
- ISA-95-aligned tag model.
- Historian + ERP + MES integrated into one semantic layer.
- OEE downtime reason codes generated from operator notes via Gen AI.
Predictive Maintenance
ML models on vibration, current, temperature, and process data - surfacing failure modes hours or days before downtime.
- Failure-mode classification per asset class.
- Maintenance work-order auto-generation with technician AI assistant.
- Closed-loop feedback so models improve with technician disposition.
Shop-Floor Copilots
Technicians get instant answers from SOPs, equipment manuals, and historical work orders - grounded in your knowledge base, with source citations.
- Tablet / mobile / handheld terminals.
- Voice-first interfaces for hands-busy environments.
- Offline-capable for plant areas with patchy connectivity.
Quality Vision & Inspection AI
Computer vision on the line for defect detection, surface inspection, and assembly verification - with re-training built into the operator UX.
- Edge-deployed for sub-second inferences.
- Operator-in-the-loop labelling for continuous improvement.
- Audit-ready logging of every inspection result.
How Our Three Service Hubs Apply to Manufacturing
AI Driven Digitalisation
MES, ERP, and historian platform modernisation. Cloud-native migration where it makes sense; safe on-prem where it does not.
Data Engineering + BI
Plant + ERP + MES unified data layer. Plant cockpits, group cockpits, OEE benchmarks, energy and emissions reporting.
Gen AI Services
Shop-floor Copilots, work order assistants, SOP search, quality deviation summarisation, supplier comms automation.
Compliance & Governance
- OT / IT segmentation respected never bridged for convenience.
- IEC 62443 awareness in plant network design.
- ISA-95 alignment in data model.
- Edge / cloud deployment patterns picked per latency and safety requirements.
Engagement Models
1
Pay for sector-specific KPI uplift - OEE, OTIF, deflection, throughput, conversion.
2
Pods of 3–7 engineers for evolving roadmaps.
3
Dedicated sector-aware delivery team. Build-Operate-Manage and Build-Operate-Transfer available.
4
Individual AI-native engineers with prior manufacturing experience.
FAQ
Frequently Asked Questions
Can you work with our existing historian and MES?
Yes. We work natively with PI, Wonderware, Ignition, GE Proficy, and most modern MES platforms. Replatforming is on the table – never a prerequisite.
How do you handle plant networks without flat-out cloud connectivity?
Edge-first design where needed. We deploy compute at the line, sync compressed data to cloud on a defined cadence, and run AI inference at the edge for sub-second loops.
What about OT cyber risk?
OT / IT remains segmented. We architect AI workflows so OT signals are consumed in read-only mode, with any control-loop action gated through your existing PLC change-management process.
Ready to Move the Metric?
Book a 60-minute manufacturing briefing. We will walk through three peer-plant case studies and put a 90-day OEE-cockpit proposal on the table.