Do we need new machines to become a smart factory?

Usually not. Most gains come from connecting and using data from equipment you already own, and from fixing process losses. New investment is recommended only where the business case supports it.

Where do you start in a plant?

With the line or asset that loses the most value. We baseline OEE, quantify the losses and start with improvements that pay back quickly, so early savings help fund the next steps.

What is a factory digital twin, and do we need one?

A digital twin is a live virtual model of your production. It earns its place when you face capacity, layout or scheduling decisions that are expensive to get wrong. If you are not there yet, we will tell you.

STEP 2 · BUILDEngineering and operations

Smart factory and production optimisation

A connected, data-driven shop floor with less downtime and higher quality.

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Where you start, where you finish

Production & operations

THIS IS FOR YOU IF

Unplanned downtime is discovered after it has already cost a shift

Nobody can give you a reliable OEE figure for your key lines

Maintenance is reactive and spare-part stock is a guess

Quality problems are found at final inspection, not at the source

Planning runs on spreadsheets that one person understands

WHAT CHANGES

Downtime becomes planned instead of discovered

Capacity decisions are made on data, not instinct

Capital decisions are de-risked by testing them in the digital twin first

FOCUS AREAS Smart factory digitalisation & optimisation Predictive maintenance Factory digital twin Increased product quality

What we do

Most plants already have the data they need to run better. It is trapped in machine controllers, spreadsheets and end-of-shift reports. We connect it, make performance visible in real time and remove the losses that matter most, starting with the ones that pay back fastest.

From deliverables to results

Concrete deliverables you keep, agreed before work starts, and the changes we measure against the business case.

WHAT YOU GET

OEE baseline per line, with the value of each loss

Prioritised improvement plan with a business case per initiative

Live production dashboards your supervisors actually use

Maintenance strategy for your critical assets

Trained teams and documented standard work

WHAT CHANGES IN YOUR BUSINESS

01Downtime becomes planned instead of discovered

02Capacity decisions are made on data, not instinct

03Capital decisions are de-risked by testing them in the digital twin first

How an engagement runs

Each stage ends with a deliverable and a decision point, so you only continue when the evidence supports it. See all engagement models.

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In practiceManufacturing, Serbia. Smart factory development support.

A European headquarters planned as a smart factory with a production digital twin

CHALLENGE

A manufacturer establishing its European headquarters in Serbia aimed for complete digitalisation and automation of the business from the start.

WHAT WE DID

The set-up is designed to increase productivity and to base business decisions on reliable data.

Read the full case study

Common questions

Often combined with

Transformation strategy & roadmap Workforce enablement & change Funding & technology selection