Industrial automation with AI
Production data lives in MES, ERP and PLCs — but not together. We connect your systems, automate quality inspection and maintenance planning, and make production KPIs usable in real time. GDPR-compliant, on-premise possible, ROI typically under 6 months.
Why classic industrial automation is not enough
Machines are automated. But the processes around them — quality, maintenance, planning — still run on Excel, paper and gut feeling.
Data silos between MES, ERP & PLC
Production data from the shop floor, orders from the ERP and machine states from the PLC sit in separate systems — manual reconciliation costs hours every day.
Unplanned downtime
Machines fail unannounced because wear patterns are not analysed. Every hour of downtime quickly costs four to five figures.
Manual quality control
Spot checks with callipers, Excel lists for SPC and after-the-fact complaints — no continuous quality flow from goods-in to delivery.
Production planning in Excel
Shift schedules, material requirements and machine allocation are maintained manually. Changes take hours, bottlenecks are spotted too late.
Compliance and audit risks
Missing batch traceability, incomplete documentation and manual inspection records put ISO audits and customer requirements at risk.
The industrial processes we automate
From machine data capture to predictive maintenance — we connect your systems and apply AI where it delivers measurable ROI.
MES & ERP integration
Machine data, orders, master data and inventory flow automatically between MES, ERP and SCADA. One data foundation, no more double entry.
AI-powered quality inspection
Computer vision detects surface defects, dimensional deviations and assembly errors in real time. Complaint rate drops, rework disappears.
Predictive maintenance
Machine data is analysed for wear patterns. Maintenance is scheduled before failures occur — instead of reacting after the standstill.
Automated production planning
Shift schedules, material requirements and machine allocation are dynamically optimised based on current orders and inventory — including bottleneck detection.
OEE & shift reporting
Asset availability, performance and quality (OEE) are captured automatically and analysed by shift, machine and order — without manual Excel work.
Batch tracking & traceability
End-to-end linking of raw material, batch, machine and finished product. On complaints, the affected batch is identified in seconds.
The ROI of industrial automation
Typical orders of magnitude from automation projects in mid-sized manufacturing — we calculate your concrete potential in the free AI audit.
How manufacturers automate maintenance, quality and planning
Three illustrative scenarios of how AI-powered industrial automation works in practice — as example calculations with typical orders of magnitude.
Predictive maintenance — downtime halved
Problem
A metalworking shop with 12 CNC machines loses around 40 hours per month to unplanned failures. Maintenance runs on fixed intervals, regardless of actual machine condition.
Solution
Vibration, current and temperature data from the spindles is analysed in real time. An AI model detects wear patterns days before failure and schedules maintenance into the next planned stop.
Result
AI visual inspection — scrap rate markedly reduced
Problem
Injection-moulded parts are inspected manually for surface defects. The sample rate is low, defective parts reach customers, the complaint rate rises.
Solution
A camera at the end of the line inspects every part with AI vision. Defective parts are rejected automatically, defect types are tracked statistically and fed back to the machine control.
Result
Production planning & batch traceability — audit-ready
Problem
Shift plans and material requirements are kept in Excel. On a complaint, tracing the affected batch takes up to two days — a risk in IFS audits.
Solution
Order, material and machine data are merged into one planning system. Every batch is linked from raw material to finished product, audits become reproducible at the press of a button.
Result
Illustrative example calculations with typical orders of magnitude — not measured values from individual clients.
Frequently asked questions about industrial automation
Answers to the most important questions about AI- and IT-driven production automation.
Classic industrial automation controls individual machines — PLCs, robots, drives. AI-powered industrial automation sits on top: it connects data from MES, ERP, SCADA and PLCs, detects patterns (e.g. wear signals, quality deviations) and automates decisions that were previously made manually — maintenance planning, quality release, production planning. It does not replace the machine, but the manual process around it.
Ready to automate your production?
In the free AI audit, we analyse your production processes and show you where the biggest lever lies — with concrete figures from your plant.
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