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AI by Industry · Manufacturing

AI, Vision & OT Security for Manufacturing Companies

Global manufacturers apply AI to the three things that decide margin: uptime, quality and planning. They run it at the edge — on the shop floor — because a cloud round-trip is too slow for a production line and too risky for a process recipe. We build the same: vision on embedded boards, sensors on your machines, forecasting on your ERP, and a hardened OT network around it.

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  • 6 moduleseach with a number attached
  • Private by defaultmodels and data on servers you own
  • Human in the loopa named person signs every decision
  • ConfidentialNDA on request, no client names

What the leaders in manufacturing require from AI

  • 01Edge first

    Inspection and monitoring run on devices beside the machine. Decisions in milliseconds, no dependence on the internet.

  • 02OT separated from IT

    PLCs, HMIs and SCADA on their own segmented network. The office e-mail PC can never reach the line.

  • 03Data owned by the plant

    Process parameters and recipes are trade secrets. They stay on the plant's servers.

  • 04Payback per line

    Each deployment is justified by scrap reduced, downtime avoided or overtime removed on a specific line.

Module by module — what AI does, what we deliver, what you measure

01

Machine Vision Quality Inspection

Cameras that inspect every part, every time, and never get tired at 3 a.m.

What the AI does

  • Detects surface defects, missing components, dimension deviations and label errors
  • Learns from a few hundred good and bad samples, refined by your QC team
  • Counts, sorts and rejects at line speed on an embedded board
  • Records images and results for traceability and customer audits

What we deliver

  • Industrial camera, lighting and edge compute (Jetson / Raspberry Pi class) installed at the station
  • Custom-trained inspection model with a review interface for QC
  • Rejection signal to PLC or pneumatic ejector
  • Defect analytics per shift, operator and batch

What you measure

Fewer customer rejections, consistent quality across shifts, and evidence for every batch.

02

Predictive Maintenance & Condition Monitoring

Vibration, current and temperature sensors that warn before a motor fails.

What the AI does

  • Learns each machine's normal signature and flags drift, imbalance and bearing wear
  • Predicts remaining useful life and schedules maintenance in the next planned stop
  • Correlates failures with load, operator and material
  • Tracks spare consumption and maintenance cost per machine

What we deliver

  • Retrofit sensor kits (ESP32 / industrial gateways) on critical machines
  • Plant dashboard with alerts to maintenance staff on WhatsApp
  • Work-order integration with your ERP or a lightweight CMMS
  • Monthly reliability report

What you measure

Unplanned downtime replaced by planned intervention, and spares bought when needed.

03

Production Planning & Demand Forecasting

A schedule built from real demand, capacity and material — updated when reality changes.

What the AI does

  • Forecasts demand per SKU from orders, seasonality and customer patterns
  • Builds a finite-capacity schedule respecting machines, tooling and shifts
  • Re-plans when a machine goes down or an urgent order arrives
  • Recommends raw-material purchase timing and quantities

What we deliver

  • Planning engine connected to Tally / ERP orders and inventory
  • Scheduler board for the production manager with drag-and-drop overrides
  • Material requirement alerts to purchase
  • OTIF (on-time-in-full) and utilisation reporting

What you measure

Better on-time delivery with less inventory and fewer overtime shifts.

04

Shop-Floor Data, OEE & Energy

Replace the register with live OEE, downtime reasons and energy per unit.

What the AI does

  • Captures machine run/stop and counts from sensors or PLC tags
  • Classifies downtime reasons and surfaces the top losses
  • Measures energy per unit produced and flags waste
  • Generates the shift report automatically

What we deliver

  • IoT gateways on machines with MQTT to a plant server
  • OEE and downtime dashboards on shop-floor screens
  • Energy metering integration and alerts
  • Automated shift and daily reports to management

What you measure

Losses made visible daily and fixed weekly, with management seeing the true OEE.

05

Supplier, Purchase & Compliance Automation

Purchase orders, invoices, test certificates and compliance documents read and filed automatically.

What the AI does

  • Extracts supplier invoices, delivery challans and material test certificates
  • Matches three-way (PO, GRN, invoice) and flags discrepancies
  • Maintains supplier scorecards from delivery and quality history
  • Prepares audit documentation for ISO and customer audits

What we deliver

  • Document extraction pipeline into Tally / ERP with review
  • Supplier performance dashboard
  • Compliance document library with expiry alerts
  • Audit pack generator

What you measure

Purchase and quality teams freed from paperwork; audits prepared in a day.

06

OT / Industrial Network Security

PLCs, HMIs and SCADA isolated and monitored so a phishing e-mail cannot stop the line.

What the AI does

  • Baselines normal PLC/HMI traffic and alerts on new connections or commands
  • Detects laptops, USB modems and remote-access tools appearing on the OT network
  • Monitors vendor remote sessions and logs every action
  • Screens office e-mail for the phishing that usually starts an OT incident

What we deliver

  • IT/OT segmentation with an industrial firewall between zones
  • Passive traffic monitoring appliance for the OT network
  • Controlled vendor remote-access gateway with MFA and session recording
  • Backup of PLC programs and HMI configurations

What you measure

Production protected from office-side incidents, and vendor access under your control.

Where manufacturers get breached

  • Ransomware crossing from office to plantAn accounts PC is phished; the flat network lets the malware reach HMIs and stop production.Our fix: IT/OT segmentation, industrial firewall, endpoint protection and monitored bridges.
  • Unmanaged vendor remote accessMachine vendors connect with shared passwords over TeamViewer; nobody knows who is in.Our fix: Remote-access gateway with named accounts, MFA, time windows and session logs.
  • Recipe and drawing theftProcess parameters and CAD files copied to a competitor via USB or personal cloud.Our fix: Data-loss controls, USB policy, access logging and exit checklist.
  • Legacy Windows on the lineHMIs on unsupported Windows cannot be patched and are exploited in minutes once reachable.Our fix: Isolation in a device zone with allow-lists, no internet, and compensating monitoring.
See the full cyber security programme →

The standard every module is built to

  • 01Private by default

    Models run on the company's own server or a private VPS. Contracts, patient records, ledgers and price lists never leave the building.

  • 02Grounded, cited answers

    Every assistant answers from the company's own documents and shows the source. When the answer is not in the data, it says so.

  • 03Human in the loop

    AI drafts, ranks, flags and forecasts. A named person approves anything that touches money, patients, contracts or people.

  • 04Measured, not assumed

    Each module starts with a baseline (hours, days, error rate, cost) and reports against it. If the number does not move, the module is redesigned.

  • 05Governed

    Access control, audit logs, model versioning and a written AI policy aligned to ISO/IEC 42001, ISO/IEC 27001 and India's DPDP Act 2023.

  • 06Owned outright

    Source code, models, prompts and data pipelines are handed over. No per-seat licence to us, ever.

Questions manufacturing leaders ask us

Our machines are old and have no data ports. Can you still monitor them?

Yes. We retrofit current, vibration, temperature and optical sensors that need no connection to the machine's controller. Most of our monitoring deployments are on machines built long before IoT.

Does vision inspection need a cloud service?

No. The model runs on an embedded board at the station. The line keeps running if the internet goes down.

How fast is payback on predictive maintenance?

It depends on the cost of one unplanned stop on your critical machine. We start with that machine and measure avoided downtime against the sensor and build cost.

Can you work with our machine vendors?

Yes. We coordinate with PLC and machine vendors for signals and remote access, and we document every integration for your maintenance team.

Free consultation

Tell us your biggest bottleneck. We'll tell you which module comes first.

Thirty minutes on the phone or at our Anna Nagar West office. You leave with a baseline to measure, a first module, and — if it makes sense — a fixed quote. No obligation.

Every client engagement is confidential. We do not publish client names, project details, screenshots or testimonials without written permission, and we sign an NDA before any assessment on request.

Want your own team trained to build this? See our Robotics & IoT Course.

Free, no obligation. We reply within one working day. Prefer to talk now? WhatsApp +91 90031 20915. Your details are confidential and never shared.

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