Smart Factory Consulting for Automotive & Mobility

We architect secure, scalable IIoT ecosystems to unify shop-floor systems with enterprise analytics:

• Edge-to-cloud data pipelines using OPC UA, MQTT, and Time-Sensitive Networking (TSN)
• Real-time equipment monitoring with predictive maintenance (PdM) models (LSTM, Random Forest)
• 5G-enabled wireless factories for low-latency control of AGVs/AMRs
• Cybersecurity hardening per IEC 62443 and NIST SP 800-82 standards

Deployed an AI-driven anomaly detection system on edge devices (NVIDIA Jetson), reducing defect escape rate by 45% while cutting unplanned downtime by 30%.

We build physics-informed digital twins to virtualize and optimize production:

• Factory layout simulation (FlexSim, Siemens Process Simulate)
• Digital thread integration linking PLM (Teamcenter), MES (Siemens Opcenter), andERP
• Closed-loop process control using reinforcement learning (RL)

• Unity3D/Omniverse for 3D factory visualization
• Reduced cycle time by 22% for a German OEM through GA-based scheduling optimization
• Edge AI and federated learning

Transform quality inspection with:

• Computer vision (CV) systems using YOLOv9 and 3D point cloud processing
• Acoustic analytics for defect detection in powertrains (FFT/Wavelet transforms)
• Statistical process control (SPC) with Apache Spark real-time analytics

• Zero-defect welding achieved for a EV chassis line via multi-spectral imaging +SVM classifiers
• Six Sigma compliance automated through PyTorch-based SPC dashboards

Design self-optimizing logistics with:

• AGV fleet orchestration via ROS 2 (DDS middleware)
• Dynamic routing algorithms (A with real-time lidar updates)
• Blockchain-tracked inbound logistics (Hyperledger Fabric)

• IIoT Platforms
• AI / ML
• Connectivity
• Cybersecurity

• PTC ThingWorx, Siemens MindSphere
• TensorFlow Lite, ONNX Runtime, MLflow
• 5G URLLC, PROFINET, EtherCAT
• Claroty, Dragos, Hardware Security Modules