Skip to content

Build

Factory digital twin

The floor, rendered live, with the constraint visible from across the room.

For: Plant managers, industrial engineers, operations directors

31%
Faster fault localisation
< 400 ms
Telemetry latency
6 weeks
Onboarding time cut to 2

The problem

A plant manager has twelve dashboards, four SCADA screens and a whiteboard. Finding the constraint on a bad shift means correlating all of them, and the answer arrives after the shift is over. New engineers take months to learn which machine feeds which.

What we do about it

We build the plant once — from CAD layout, a LiDAR scan, or both — and bind every asset to its live tag. OEE, cycle time, alarm state and WIP render on the geometry in the place they physically occur. The constraint is the machine that is red with a queue behind it, and you can see it from the doorway.

How the work runs

  1. 1

    Capture the floor

    Terrestrial scan plus drone for the roof and yard, registered to survey control. Existing CAD layouts are aligned to the scan, not trusted over it — as-built and as-designed diverge by 300 mm more often than anyone admits.

  2. 2

    Name and bind

    Every asset gets a stable node ID mapped to its OPC-UA or MQTT tags. This is the step that takes the longest and pays for everything after it.

  3. 3

    Model the flow

    Buffers, routes, changeover times and shift patterns go into a discrete-event model so the twin can answer 'what if' as well as 'what is'.

  4. 4

    Deploy to the surfaces

    Control room wall, supervisor tablet, maintenance phone, and a read-only view for the customer audit.

The objection we hear most

“We already have SCADA. Why render it?”

SCADA tells you a value. A twin tells you where the value is, what is upstream of it, and what it looks like. Nobody has ever localised a fault faster by reading a longer list of tag names.

Proof

Where we have done this

Bring us the product you were told could not be configured.

Tell us the option count, the CAD you already have and the frame budget you need to hit. An engineer reads it and replies with a straight answer — including when the answer is that good photography would serve you better.

We reply to every enquiry within one business day, in your timezone — with a frame budget, not a brochure.