Smart factories and digital twins for a global manufacturer

The challenge

A global manufacturing enterprise was losing output to unplanned downtime and lacked real-time visibility across its plants. Maintenance was largely reactive, and there was no unified view to model and optimise production.

What we did

We deployed IoT sensors, predictive-maintenance AI, and digital twin technology across five manufacturing facilities. Real-time monitoring dashboards gave plant teams live visibility, predictive models flagged failures before they happened, and digital twins let the business simulate and optimise production planning and scheduling.

The impact

Unplanned downtime fell sharply, maintenance shifted from reactive to predictive, and the enterprise now has a connected, data-driven foundation for continuous improvement across its operations.

Representative engagement illustrating the type of work we deliver. The client identity and certain figures are anonymised or generalised to respect confidentiality agreements.