SOLUTIONS
Solutions
No single technology solves shop-floor challenges on its own. The Foundry combines six solutions on a shared data platform to optimise the whole plant.
01 / DIGITAL TWIN
Digital Twin
We recreate your plant's equipment, processes, people and material flows in a virtual space. Beyond monitoring live operations, you can simulate "what if" scenarios and validate improvements without stopping the line.
Recommended if
- You want to launch new lines or change layouts faster and with less risk
- You want a single view of operations across multiple plants from headquarters
- You want to pinpoint bottleneck processes quantitatively
Key capabilities
| Real-time monitoring | PLC and sensor data overlaid on the 3D model |
|---|---|
| Process simulation | Evaluate capacity before volume increases, new products or staffing changes |
| Cross-site dashboard | Compare OEE, quality and energy across global sites |
02 / PREDICTIVE MAINTENANCE
Predictive Maintenance
AI continuously watches vibration, current, temperature and acoustic data to catch early signs of failure. Remaining-life prediction optimises part replacement so maintenance fits inside planned stops.
Recommended if
- You want to cut production losses from unplanned downtime
- You want to move from time-based to condition-based maintenance
- You want to reduce the burden of manual inspection rounds
Key capabilities
| Anomaly detection | Unsupervised models that learn from normal data only |
|---|---|
| Remaining useful life (RUL) | Predict replacement timing to the day from degradation trends |
| Maintenance integration | Automatically raise work orders in your CMMS |
03 / VISION INSPECTION
Vision Inspection
Image AI judges scratches, dents, foreign matter, print defects and dimensional errors quickly and consistently. Because it can learn mainly from good-part images, you can start even when defect samples are scarce.
Recommended if
- Inspectors are hard to hire and inspection quality varies
- You want to move from sampling to 100% inspection
- You want defect trends to drive upstream improvements
Key capabilities
| Inline judgement | Runs on edge devices, in step with your takt time |
|---|---|
| Explainable results | Heatmaps show defect locations for final human review |
| Continuous learning | Models improve regularly from shop-floor feedback |
04 / KNOWLEDGE AI
Knowledge AI
Work standards, drawings, incident reports, operating logs and interviews with experts: generative AI structures this scattered knowledge into a "veteran on call" that anyone can question in plain language.
Recommended if
- You worry about losing know-how as experts retire
- You want new and international workers productive sooner
- You want past incidents at your fingertips when you need them
Key capabilities
| Shop-floor Q&A | Answers with sources; tablet, voice input and multilingual |
|---|---|
| Tacit-knowledge capture | An AI interviewer draws out and documents expert judgement |
| Knowledge graph | Links equipment, parts, failures and countermeasures |
05 / PRODUCTION PLANNING
Production Planning
Mathematical optimisation and AI build feasible plans automatically, accounting for orders, inventory, capacity, changeover times and staff skills. When rush orders or breakdowns hit, a re-plan that minimises impact is ready in minutes.
Recommended if
- Planning depends on spreadsheets and one person's experience
- You want fewer and shorter changeovers
- You want on-time delivery and lower inventory at the same time
Key capabilities
| Automatic scheduling | Multiple plan options that satisfy every constraint |
|---|---|
| Demand forecasting | Forecasts from history, seasonality and external data |
| What-if analysis | Compare KPI impact before changing the plan |
06 / GREEN TRANSFORMATION
Green Transformation
We make energy use and CO₂ emissions visible down to each asset, and AI optimises how HVAC, compressors, boilers and furnaces run. Decarbonise and cut costs together, without sacrificing quality or productivity.
Recommended if
- You need to respond to soaring energy costs
- You need Scope 1, 2 and 3 calculation and disclosure
- You want to prove the impact of reduction measures with numbers
Key capabilities
| Energy visibility | Energy intensity by asset, line and product |
|---|---|
| Operations optimisation | Run schedules proposed automatically from demand forecasts |
| CO₂ accounting & reporting | Scope 1–3 calculation and disclosure-ready reports |