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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.

Explore a live interactive demo of the digital twin dashboard — see machine monitoring, OEE tracking, and AI maintenance alerts in action.

No commitment required. Explore the dashboard at your own pace.