01
Vision-based quality inspection
In-line defect detection and classification on surfaces, welds, assemblies and print. Runs at line rate on edge hardware, with a review loop that keeps producing labelled data.
- Moves
- Scrap and escape rate
03 Industrial practice
Digital transformation that reaches the shop floor.
Not a portal, not a dashboard programme. Industry 4.0 delivered as systems that change what a line does — engineered for brownfield reality, segmented networks and people who will judge them on a night shift.
01 Where the value sits
Six places industrial AI reliably pays.
Chosen because the decision is frequent, the ground truth is obtainable, and the improvement is measurable on a P&L rather than in a slide.
02
Predictive maintenance
Asset health from vibration, current, thermal and process telemetry. Ranked by remaining useful life and by what a failure actually costs, not by anomaly score.
- Moves
- Unplanned downtime
03
Throughput & yield optimisation
Constraint identification across the line, then closed-loop or advisory set-point recommendation. Usually the highest-return work and the least glamorous.
- Moves
- OEE and first-pass yield
04
Shop-floor data foundation
The unglamorous prerequisite: OPC UA / MQTT collection, contextualisation against asset hierarchy, historian and lakehouse landing, quality monitoring.
- Moves
- Time to answer a question
05
Digital twin & process simulation
Calibrated models used to evaluate a change before committing the line to it — scheduling, energy, changeover and capacity scenarios.
- Moves
- Cost of experimentation
06
Agent-assisted operations
Retrieval and agentic assistance over SOPs, maintenance history, drawings and tribal knowledge, delivered where the work happens. Cited, sandboxed, and safe to be wrong out loud.
- Moves
- Time to competence
02 Industry 4.0 scope
The operations backbone the intelligence depends on.
AI only pays on top of disciplined execution, quality and data. These are the Industry 4.0 capabilities we engineer, integrate and modernise around your existing MES, ERP and automation — rather than replacing them by default.
01
MES & manufacturing operations
Modernisation, extension and integration of manufacturing execution — electronic work instructions, routing, dispatching, labour, equipment and WIP tracking. Commercial MES platforms integrated and extended; purpose-built execution layers where a platform does not fit.
- Moves
- Schedule adherence and WIP visibility
02
Quality management & SPC
Statistical process control at the point of production, non-conformance and deviation handling, and CAPA workflows — with inspection and metrology results closed back into the process rather than filed in a report.
- Moves
- Cost of poor quality
03
Traceability & genealogy
Lot, batch, serial and component-level genealogy from raw material to shipped unit. As-built records, supplier and customer data exchange, and recall scoping measured in minutes rather than days.
- Moves
- Recall scope and response time
04
OT cybersecurity
OT asset inventory and exposure assessment, IEC 62443 zone-and-conduit design, segmentation, secure remote access and OT-aware monitoring — engineered with operations so that security never becomes the reason the line stops.
- Moves
- OT attack surface
05
Regulated & validated manufacturing
Electronic records and signatures, audit trails and computer system validation aligned to 21 CFR Part 11, EU GMP Annex 11 and GAMP 5 — with IQ/OQ/PQ evidence produced during delivery, not reconstructed for the audit.
- Moves
- Validation effort per release
06
Planning, scheduling & material flow
Finite-capacity planning and scheduling, rule-based dispatching, kitting and line-side logistics, warehouse integration and AGV / AMR orchestration — driven by live shop-floor state rather than yesterday’s plan.
- Moves
- On-time delivery and changeover loss
07
Vertical & horizontal integration
An ISA-95-aligned data model and Unified Namespace connecting equipment, MES, ERP, PLM and LIMS — then extended across plants, suppliers and customers so every site answers the same question the same way.
- Moves
- Time to bring the next site online
08
Connected worker, mobility & AR
Mobile-first operator and technician tools, digital checklists, skills and certification enforcement at the point of work, and augmented-reality overlays of live process data on the equipment itself.
- Moves
- First-time-right execution
09
Energy & sustainability
Metering at line and asset level, energy per unit as a first-class production KPI, demand shaping, and the auditable emissions data trail that ESG and customer sustainability reporting now require.
- Moves
- Energy per unit produced
Industries served
- Semiconductor & advanced packaging
- Electronics, SMT & EMS
- Medical devices
- Automotive & EV components
- Batteries & energy storage
- Industrial equipment & machinery
- Aerospace & precision engineering
- Pharmaceutical & process
- Energy, utilities & oil and gas
We are platform-neutral. Where a commercial MES, QMS or historian is already in place, we integrate, extend and harden it; where none fits, we build the narrow execution layer that is missing. The recommendation follows the constraint, not a partnership quota.
03 Reference architecture
Six layers, from the sensor to the decision.
A shape, not a product list. Every engagement adapts it — but the layering, the contracts between layers and the direction of dependency stay fixed.
L5
Applications & decisions
- Operator UI
- Planner tooling
- Quality & SPC
- Alerting
- Reporting
- Mobile, HMI & AR
L4
Intelligence
- Vision models
- Forecasting
- Optimisers
- Scheduling
- Twins
- Retrieval & agents
L3
Data platform & operations
- Lakehouse
- Time-series store
- Feature store
- Semantic layer
- MES / MOM
- Genealogy
- Governance
L2
Streaming & contextualisation
- Unified Namespace
- Kafka / Sparkplug B
- Stream processing
- ISA-95 asset model
- Unit & schema contracts
L1
Edge & gateway
- OPC UA collection
- Protocol translation
- Edge inference
- Store-and-forward
- Fleet management
- Secure remote access
L0
Process & OT
- PLC / SCADA
- Sensors & vision
- Historians
- Robotics & AGV / AMR
- Safety systems
Data and context flow upward · control and intent flow down · contracts at every boundary
04 Design constraints
What industrial software has to survive.
These are not caveats. They are the design inputs that separate systems which get adopted from systems which get bypassed.
Brownfield is the default
Equipment from four decades, three protocols and two acquisitions. We design for what is on the floor, not for a reference architecture diagram.
The line does not stop
Integration work is planned around production windows and validated in a way that does not require faith. Rollback is rehearsed before rollout.
Segmentation and air gaps
Purdue-model boundaries, IEC 62443 zones and conduits, one-way data diodes and sites with no cloud egress at all. Edge-first designs, offline capable, with sync as an optimisation.
Safety and audit are non-negotiable
Nothing we build sits in a safety-instrumented loop without an explicit, reviewed hazard analysis. Change control and validation records are produced as we go, to the standard a regulator would expect.
Operators decide adoption
A system that gets routed around has failed regardless of its metrics. We design with the shift, not for a stakeholder in a different building.
Skills have to remain in-house
Your maintenance and automation engineers are the long-term owners. Enablement is part of the plan, not a closing workshop.
05 First engagement
Narrow scope, undeniable result.
The shape of a first engagement with a manufacturer. Deliberately narrow — one cell, one constraint, one measurable outcome your own people can verify.
-
Stage one
01 Walk, measure, size
- Process walk with operators and maintenance
- Data readiness and sensor audit
- Ground-truth definition and baseline capture
- Option set with costs and expected effect
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Stage two
02 Prove on your data
- Working system on real production data
- Evaluation harness with slice reporting
- Edge deployment on representative hardware
- Shadow mode alongside the current process
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Stage three
03 Operate and decide
- Progressive cut-over with rollback rehearsed
- Operator enablement and runbooks
- Measured delta against the baseline
- Scale-out plan or an honest stop
"An honest stop" is a real outcome. A meaningful share of diagnostics conclude that the economics do not support the project yet — usually because the ground truth is not obtainable at acceptable cost. Establishing that before a programme is committed is the cheapest finding available.
Manufacturing brief
One line, one constraint, one measurable outcome.
Tell us about the line, the data you have, and the number you are trying to move. We will come back with an honest read on tractability and a costed option set — or a recommendation to fix something else first.
or write directly — [email protected]