Industrial AI co-innovation hub for manufacturing, plants and energy
NEWAutumn 2026: our Tokyo co-innovation lab expands
TCS Industrial Intelligence Foundry is an industrial AI co-innovation hub for manufacturing, plant and energy companies. Digital twins, predictive maintenance, vision inspection, knowledge transfer: we turn ideas into AI that runs on the shop floor, starting with an 8-week PoC.
Overall equipment effectiveness (OEE)
87.2%
▲ 6.4pt YoY
Predictive alerts (today)
3
● 1 needs review
CO₂ emissions (monthly)
−18%
▼ On track for target
PREDICTIVE ALERTPress #3 spindle bearing shows signs of wear. Remaining life approx. 14 days. Replace during the next planned stop (Oct 29).
LIVE DEMO
Experience the Foundry's technology in applications that really run: AI avatars you can talk to and a Physical AI platform that moves robots. Connected, they unite listening, learning and acting on the shop floor.
PHYSICAL AI PLATFORM
Capture expert know-how, train skills in simulation and execute on UR5e arms and humanoids. Genesis physics and a digital twin validate every move before it reaches the floor.
DIGITAL HUMAN
AI avatars rendered live in the browser answer by voice and understand the scene through the camera: a shop-floor guide, an expert interviewer and a multilingual work assistant.
* "Try it live" embeds the real applications (sign-in required). Integration between the two apps is at the concept stage.
CHALLENGES
Labour shortages, retiring experts, rising energy prices. The challenges facing manufacturers grow more complex every year.
Changeovers and judgement calls during abnormal events depend on a few veterans, and knowledge transfer can't keep up.
Stuck on time-based maintenance, with parts costs and downtime both climbing.
Inspectors are hard to hire, and missed or false defects cause rework and scrap.
PLC, MES and ERP data don't connect, so cross-site analysis and decisions are out of reach.
Scope 1 and 2 are visible now, but concrete reduction measures are hard to find.
The PoC succeeded, yet adoption on the floor and enterprise-wide rollout stall.
The Foundry solves them
with AI that works on the shop floor.
ABOUT
A foundry is where metal is melted and cast into shape. We take the data sleeping on your shop floor and the wisdom of your experts, melt them together, and cast them into AI that actually gets used on the floor.
One team of specialists who understand both OT (control systems and equipment) and IT (business systems) stays with you from building the data platform and developing AI models to embedding them in daily operations.
▲ INSIGHT
▲ CONTEXT
▲ DATA
CO-CREATE
Workshops that bring operations, management and IT together to identify the themes with the highest return.
BUILD
An 8-week PoC on real data proves value and fit with operations, designed from day one with production in mind.
SCALE
Take one line's success to multiple plants and global sites, with operations (MLOps) and talent development included.
SOLUTIONS
We combine six solution areas to match the challenges on your shop floor.
VIRTUAL FACTORY
A virtual replica of your plant, equipment and processes for real-time monitoring and simulating layout changes or ramp-ups.
CONDITION-BASED
Detect early signs of failure from vibration, current and temperature data. Prevent breakdowns and move to condition-based maintenance.
COMPUTER VISION
Image AI that flags scratches, foreign matter and dimensional defects. Learns from few defect samples, reducing both workload and misses.
GENERATIVE AI
Generative AI structures work standards, incident reports and expert interviews, so anyone on the floor can simply ask a veteran.
OPTIMISATION
Orders, inventory, capacity and staffing feed mathematical optimisation and AI to build plans automatically, and re-plan instantly for rush orders.
ENERGY & CO₂
See energy use across the plant and let AI optimise HVAC, compressors and furnaces, cutting CO₂ and cost at the same time.
NUMBERS
Manufacturers supported worldwide
0+
TCS group-wide
PoCs that moved to production
0%
Foundry engagements
Standard PoC duration
0wks
After assessment
Industrial AI specialists
0+
Japan, India, Europe
CASE STUDIES
Foundry AI is running on shop floors across industries and company sizes.
Major automotive parts maker A / approx. 12,000 employees
Diversified chemical company B / 5 sites in Japan
Food manufacturer C / 12 packaging lines
FLOW
A staged approach from first conversation to enterprise rollout keeps investment risk low. You decide whether to continue at every step.
STEP
We listen to your challenges and outline where AI can help.
STEP
Site diagnosis and data review to prioritise themes and quantify ROI.
STEP
Build AI on real data and validate value and operational fit.
STEP
Integrate with existing systems in a form operators keep using.
STEP
Roll out to more lines and sites, with operations, improvement and training.
* Durations are typical guidelines and vary with scope and data readiness.
WHY FOUNDRY
REASON01
Control and equipment engineers sit on the same team as data scientists. We speak the language of the shop floor, so requirements don't get lost.
REASON02
Even the PoC is built on an architecture ready for production and rollout. We don't stop at validation.
REASON03
Experience and assets from manufacturers worldwide, adapted to Japanese operations: faster and surer than starting from scratch.
REASON04
On-premises and edge architectures keep plant data in-house, backed by bilingual support and long-term operations.
NEWS
FAQ
Of course. Many clients come to us not knowing where to start. We help structure your challenges from the very beginning. The first 60-minute online consultation is free.
A standard PoC takes 8 weeks. Cost depends on scope and data readiness, so we provide a quote based on the results of a 2–4 week assessment.
Yes. We propose architectures that fit your security policy, including fully on-premises or edge deployments and private network connections.
We can start by building data collection: selecting and installing sensors and extracting data from existing equipment. We also use techniques that learn from small datasets and simulation-generated data.
Yes. Using standard protocols such as OPC UA and MQTT plus APIs, we integrate with what you already have, without locking you into a single vendor.
We offer operations and maintenance (MLOps), model retraining and continuous improvement, plus training programmes to build data and AI talent inside your organisation.
CONTACT
A specialist consultant will get back to you within two business days. Free 60-minute online consultations are available.