Industry 4.0 Smart Manufacturing
Pinpointing digital-twin solutions to deliver double-digit OEE gains in 1980s-era brownfield plants while satisfying strict cybersecurity requirements and a ≤24-month payback period.
Client
Multinational Manufacturer
Objective
Deliver ≥15% Downtime Reduction
Timeline
10-Week Program
Key Focus
Brownfield Retrofits & ROI
The Challenge: Three Roadblocks to Plant-Wide Adoption
Digital twins promise 10-20% OEE improvements, but their rollout in existing "brownfield" facilities is prevented by three major roadblocks.
1 High-Fidelity Models
Accurately modeling the complex multiphysics of legacy assets can demand HPC-class compute and scarce domain expertise.
2 Secure OT/IT Convergence
Moving sensor data from the shop floor to the cloud must meet strict IEC 62443 zero-trust security requirements without adding latency.
3 ROI Justification
The high cost of retrofitting sensors and integrating models must provide a clear payback in ≤24 months to win budget approval.
Key Outcomes: Five Lead Options for a Secure Retrofit
Our 6-phase sprint delivered a shortlist of five solutions—from hybrid AI twins to plug-and-play sensor kits—that met the client's stringent performance, security, and financial targets.
Simulated Impact (Year 1)
18%
Downtime Cut
11%
Energy Saving
Strategic Impact
Armed with validated data and a secure roadmap, the manufacturer green-lit a 15-asset pilot using the GNN twin and zero-trust gateway. Successful scale-up will position the firm as an Industry 4.0 leader, boosting productivity and cyber resilience.