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Digital Twin for
Smarter Factories

Connect your machines, production lines, and factory operations into one live digital twin. Get real-time visibility, AI-driven insights, and predictive maintenance — without a massive transformation project.

24/7 Live Visibility
Real-time OEE Tracking
AI Maintenance Copilot
Alphanso AI — Factory Digital Twin
81% Line OEE
2.4h Downtime
12 Machines
CNC-01
Vibration: Normal
94%
Press-02
Temperature: High
72%
Line-03
OEE: 81% — On target
81%
Pump-04
Downtime: 38 min — Alarm A12
45%
🤖 AI Alert: Press-02 shows rising temperature. Inspect cooling system and bearing lubrication within 24 hours.

Everything Your Factory Needs

Six integrated capabilities that give operations teams live visibility, AI-driven insights, and actionable intelligence across every machine and production line.

📊

OEE & Downtime Tracking

Track availability, performance, and quality across all machines with automatic downtime classification and shift-wise reporting.

🔮

Predictive Maintenance

Detect abnormal patterns in temperature, vibration, current, and cycle time before they escalate into costly unplanned stoppages.

Energy Insights

Monitor energy consumption by machine and line. Identify wastage during idle periods, overload conditions, and inefficient cycles.

🤖

AI Maintenance Copilot

Ask natural-language questions about machine health, downtime causes, SOPs, and maintenance history for instant AI-powered guidance.

📡

Live Machine Monitoring

Real-time visibility into running, idle, stopped, and alarm states for every asset — from CNC machines to compressors and presses.

🔔

Real-time Alerts & Reports

Automated alerts for abnormal machine behavior and scheduled performance reports for operations review and management dashboards.

Three Integrated Modules

Each module delivers standalone value while working together as a complete factory intelligence platform.

⚡ Module 01
🏭

Live Machine Monitoring

Connect machine, PLC, SCADA, sensor, and manual production data into one live dashboard with real-time status and intelligent alerts.

What you get
  • Running, idle, stopped & alarm states
  • Temperature, vibration, pressure & energy data
  • Line-level and machine-level visibility
  • Real-time production status monitoring
  • Alerts for abnormal machine behavior
📡 Real-time data — updated every second
📊 Module 02
📈

OEE & Downtime Intelligence

Identify where production is slowing, why machines stop, and which losses impact output the most with deep operational analytics.

What you get
  • Availability, performance & quality tracking
  • Downtime reason classification and logging
  • Shift-wise and machine-wise performance reports
  • Production bottleneck identification
  • Daily and weekly performance summaries
🎯 Avg. 12% OEE improvement in 90 days
🤖 Module 03
🤖

AI Maintenance Copilot

Use AI to assist maintenance teams with alerts, troubleshooting guidance, SOPs, manuals, and historical logs through natural language.

What you get
  • Anomaly detection and early warning alerts
  • Root-cause suggestions for alarms & stoppages
  • Maintenance recommendations & task scheduling
  • Natural-language queries about any machine
  • AI search over manuals, SOPs & logs
🧠 Answers in < 3 seconds from any device

Measurable Impact for Your Operations

Built for plant heads, production teams, and maintenance leaders who need real results, not just dashboards.

📉

Reduce Unplanned Downtime

Detect abnormal machine behavior early and help teams act before failures become expensive stoppages that halt production lines.

📈

Improve OEE

Track availability, performance, and quality across machines and production lines in near real time for continuous improvement.

Optimize Energy Usage

Monitor energy patterns by machine or line and identify wastage during idle, overload, or inefficient operating cycles.

🔧

Improve Maintenance Planning

Move from reactive maintenance to condition-based and predictive maintenance workflows that reduce emergency repairs and costs.

🔍

Find Bottlenecks Faster

See which machine, shift, process, or downtime reason is limiting your daily output and take targeted corrective action.

💡

Make Factory Data Usable

Convert disconnected machine data, logs, manuals, and reports into decision-ready insights for your entire operations team.

From Machines to AI Insights

A connected digital twin layer built on your existing industrial systems. Start with selected machines and expand plant-wide at your own pace.

🏭
Layer 1
Machines
  • PLCs
  • CNC machines
  • Sensors
  • Energy meters
  • Compressors
  • Presses & pumps
🔌
Layer 2
Connectivity
  • OPC UA
  • Modbus
  • MQTT
  • REST APIs
  • SCADA / MES
  • ERP / CSV / SQL
🖥️
Layer 3
Edge Agent
  • Edge gateway
  • Local buffering
  • Preprocessing
  • Offline support
  • Secure upload
☁️
Layer 4
Cloud Backend
  • APIs
  • Event pipeline
  • Authentication
  • Data validation
  • Role-based access
🗄️
Layer 5
Data Store
  • Time-series DB
  • PostgreSQL
  • Object storage
  • Vector database
  • Historical records
🤖
Layer 6
AI Layer
  • Anomaly detection
  • Predictive insights
  • Root-cause AI
  • NL query engine
  • Pattern analysis
📊
Layer 7
Dashboard
  • OEE dashboard
  • Downtime reports
  • Energy view
  • Maintenance view
  • Mobile-friendly

Your Factory, Live

A unified view of machine status, OEE performance, and AI maintenance alerts — all in one real-time digital twin dashboard.

Alphanso AI — Production Line Digital Twin

Production Line Overview

Live
Line OEE
81%
▲ 3.2% vs yesterday
Downtime Today
2.4 h
▼ 1.2 h unplanned
Machines Active
10 / 12
2 in maintenance
Energy Usage
324 kW
▲ Within target
CNC-01
● Running
Health94%
VibrationNormal
Temp72 °C
Press-02
⚠ Warning
Health72%
TemperatureHigh
AlertA-07
Line-03
● Running
OEE81%
OutputOn target
Quality99.2%
Pump-04
■ Stopped
Downtime38 min
AlarmA12
CauseUnder review
🤖
AI Maintenance Alert
Press-02 shows a rising temperature pattern over the last 4 hours. Recommend inspecting the cooling system and bearing lubrication within 24 hours to prevent unplanned stoppage.

Ask Your Factory Anything

Natural-language queries over machine data, maintenance logs, SOPs, and historical records. Instant AI-powered answers for every shift.

Example queries your team can ask:

💬 "Why did Line 2 stop yesterday?"
💬 "Which machine had the highest downtime this week?"
💬 "What should the technician check for alarm A12?"
💬 "Show me abnormal vibration trends for CNC-01."
💬 "What's the OEE for the morning shift today?"
💬 "What does the SOP say about Press-02 maintenance?"
🤖
Alphanso Copilot
● Online
👤
Why did Line 2 stop yesterday?
🤖
Line 2 had 3 stoppages totaling 2.4 hours. The primary cause was Pump-04 triggering alarm A12 at 14:32 (cooling pressure drop). The second stoppage at 17:10 was a planned shift changeover.
👤
What should we check for alarm A12?
🤖
Per the Pump-04 SOP (Section 4.2), alarm A12 indicates low cooling pressure. Check: 1) Coolant level, 2) Pump inlet filter, 3) Pressure relief valve setting. Last similar alarm was resolved in 22 min.

From Audit to Live Digital Twin

A clear, structured path from factory assessment to a fully operational digital twin with AI insights and a plant-wide scale-up roadmap.

1
⏱ Week 1 – 2
🔍

Discovery & Data Audit

Identify critical machines, available sensors, PLC/SCADA/MES/ERP access, and the highest-value first use case.

  • Understand factory layout
  • Identify critical lines
  • Review machine data
  • Check system availability
  • Define use case
✓  Factory readiness report delivered
2
⏱ Week 3 – 4
🎯

Pilot Scope Definition

Select one production line or group of critical machines. Define KPIs: OEE, downtime, energy, and maintenance alerts.

  • Select pilot machines
  • Define dashboards
  • Finalize data sources
  • Set alert rules
  • Align stakeholders
✓  Signed-off pilot scope & KPI plan
3
⏱ Week 5 – 8
⚙️

Integration & Build

Connect machine data through edge gateways and build real-time dashboards, alerts, reports, and asset hierarchy.

  • Connect machine data
  • Configure pipelines
  • Build asset hierarchy
  • Develop dashboards
  • Validate accuracy
✓  Live dashboard & real-time alerts
4
⏱ Week 9 – 12
🚀

AI Insights & Scale-Up

Deploy anomaly detection, maintenance copilot, impact reports, and a plant-wide rollout roadmap for full expansion.

  • Analyze machine trends
  • Build AI alerts
  • Enable AI copilot
  • Generate reports
  • Prepare scale-up plan
✓  ROI report & factory-wide roadmap

Built for Manufacturers Who Care About Uptime

Best suited for factories where downtime, output, quality, or energy usage drives daily performance and profitability.

🚗 Auto Components
⚙️ CNC & Engineering Units
🧴 Plastic Injection Molding
🧵 Textile Processing
💊 Pharma Manufacturing
🍎 Food & FMCG Plants
📦 Packaging Lines
☀️ Solar Module Manufacturing
🧪 Chemicals
⚡ High Energy-Use Plants

Start With One Production Line.
Prove the Value. Then Scale.

Request a pilot discussion and we'll help you identify the right use case, connect available data, build live visibility, and create an AI-powered roadmap for your factory.

No commitment required. Start with a discovery call about your factory's specific needs.