Operational excellence

Productivity with data science

Unfold the blind spots in your production process – even on legacy equipment – and raise productivity end to end.

The opportunity

Integrated processes are the biggest remaining source of productivity

Industries must continually raise productivity to keep pace with market demand and competition. Individual machines have already been optimised in isolation, making further ROI harder to achieve. Contextualising the process across an end-to-end, integrated data layer enables data science and machine learning to model the next productivity gains.

What stands in the way

Much of the installed equipment is old enough that it was never built to generate the data points needed to understand the context. Blind spots prevent a full view of cause and effect across the production process, and retrofitting sensors is expensive and may not deliver ROI – particularly for proprietary vendor software that does not integrate with other platforms.

A welcome side effect

The models capture the process know-how of experienced staff. It stays in your company and keeps quality consistent – even when people leave.

How it works

From isolated machines to soft sensors

Individual machines are digitally mature, but the dependencies and interactions in the overall system are rarely addressed.

01

Isolated sub-systems

Vendor solutions, data spread across PLCs, sensors, MES and ERP – or not captured at all.

02

Baseline Digital Twin

All PLC and sensor tags plus the energy signal (Watt) every motor provides are structured in a Unified Namespace – on any asset, regardless of age or vendor.

03

Soft sensors

Data science and process expertise build soft sensors that infer parameters with no physical sensor.

04

Harvest productivity from machine learning

Machine learning models the productivity gains – from predictive maintenance and energy savings to end-to-end process optimisation.

Platform architecture from IoT data sources to applications

The architecture

From IoT data to applications in your plant

Connectivity and data collection, a Unified Namespace as Baseline Digital Twin, soft sensors that combine artificial intelligence with your process knowledge – and applications from performance intelligence to predictive maintenance. Data sovereignty and process expertise remain with you.

Technology partners

Enabled by proven technology

Octotronic logo

Digital twin technology enabled by OctoCore from Octotronic

symmedia logo

Secure connectivity enabled by symmedia

Yukawa logo

Data lakehouse technology enabled by Yukawa

One language for everyone

Cryptic machine tags become readable measurements for everyone

The Unified Namespace structures the data; the ontology on top gives it meaning – turning fragmented, heterogeneous sources into a model every stakeholder can read, not only data scientists. Vendor-neutral by design.

Cryptic machine tags become readable measurements for everyone.
From isolated sub-systems to a Baseline Digital Twin to Soft-Sensor-based measurement and control

Soft sensors via the models

From isolated sub-systems to soft-sensor-based control

Data science and process knowledge fill the blind spots in the digital twin, and the learned pattern transfers across a fleet – including older, sparsely-instrumented assets.

Potential

What it delivers in your plant

Once the blind spots are closed, data science can model the productivity gains.

Predictive maintenance

Detect wear and failures before they stop production.

Automation

Automate what is understood – step by step.

Energy savings

Make energy consumption visible and reduce it.

Process optimisation

Optimise the production process end to end.

Knowledge through LLMs

Make process knowledge available to everyone who needs it.

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Become a pilot customer

We are looking for process industry operators who want to validate the Baseline Digital Twin in their brownfield plant.