Manufacturing companies lose money not on machines, but on data about machines. A digital twin shows you the real operation in real time, without having to replace your existing infrastructure. The principle is always "no rip and replace".
Who it's for
- Serial and one-off production, OEE, predictive maintenance, traceability
- Process industry, chemical, food, pharmaceutical operations
- Warehousing and logistics, condition monitoring, flow automation
- Maintenance organizations, predictive and condition-based maintenance instead of reactive
Typical assignments we solve
- Digital twin of a production line, real-time OEE dashboard, alerts when deviating outside tolerance, predictive maintenance. The team sees the problem hours before the failure, not after
- ERP ↔ MES ↔ SCADA integration, production data side by side with financial data in a single view. Management sees performance and costs together (more in Integrations)
- Production energy management, sub-metering across halls and technologies, identification of waste
- AI process optimization, models over telemetry that recommend parameter settings for optimal quality/yield (more in AI solutions)
- Production document data extraction, an AI agent pulls structured data from production orders, delivery notes, and inspection protocols into the ERP
- Field service for critical equipment, our own team from three branches (more in Field service)
- Mobile monitoring of large sites, for construction sites, expansions, or rotating projects we can deploy TechTower
We typically see a 15–40% reduction in non-productive time and a 20–35% drop in unplanned outage costs after the first year of digital twin operation.
Stack and principles
- Platform: KALM:IT (our own, cloud or on-prem, data in the EU)
- Protocols: Modbus, OPC-UA, BACnet, MQTT, custom protocols
- CRM/ticketing for processes around production: omniHub (custom CRM with no per-user fees)
- Security: ISO certifications, end-to-end encryption, audit log
Want to see where the hidden losses are on your shop floor?
Schedule an operations audit, the first dashboard typically within 2 weeks of signing.
