Reduce downtime, optimize operations, and improve quality with predictive analytics and IoT solutions
Irish manufacturers face increasing pressure to improve efficiency while managing aging equipment and rising costs.
Equipment failures cause costly production stoppages. Emergency repairs are expensive and disruptive. Struggling to predict when machines will fail.
Can't identify bottlenecks until they become critical. Production data is fragmented. No clear visibility into OEE (Overall Equipment Effectiveness).
Either over-maintaining equipment (wasting money) or under-maintaining (risking failures). No data-driven maintenance scheduling.
Defects discovered too late in the process. Manual quality checks are slow and inconsistent. Difficulty tracing root causes of quality problems.
Can't predict raw material needs accurately. Supplier delays impact production schedules. Excess inventory ties up working capital.
Energy costs, labor costs, and material costs all increasing. Need to do more with less but lack data to optimize spending.
The Problem: Calendar-based maintenance doesn't account for actual equipment condition. Waste money maintaining equipment that doesn't need it, miss failures that happen between intervals.
The Problem: Labor-intensive, prone to human error. Can't catch subtle warning signs. By the time problems are visible, it's often too late.
The Problem: Collect data but don't provide predictive insights. Require manual interpretation. Limited alerting capabilities.
The Problem: Can't handle complexity of modern manufacturing. No integration with real-time production data. Decisions based on outdated information.
Industry 4.0 solutions designed specifically for the challenges faced by Irish manufacturing SMBs. Each solution integrates seamlessly with your existing systems.
Start with a free assessment to see which solutions are right for your facility. No commitment, no credit card required.
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Smart sensors that monitor equipment health 24/7
AI predicts failures before they happen
€150K-€300K annual cost reduction
Not enterprise-scale complexity or cost. Solutions sized for 20-250 employee manufacturers. Rapid ROI focus.
Retrofit IoT sensors to existing machines—no need to replace equipment. Compatible with older SCADA and PLC systems.
Implement during scheduled maintenance windows. Pilot on one production line before full rollout. No need to halt operations.
Clients typically see €150K-€300K annual savings from reduced downtime, lower maintenance costs, and improved efficiency.
Team includes former manufacturing engineers who understand production environments. Not just tech consultants.
On-premise or hybrid cloud options. Air-gapped critical systems. 99.9%+ uptime SLA.
Combining Industrial IoT, machine learning, and manufacturing domain expertise to deliver measurable improvements.
Our advanced monitoring systems track equipment health, predict failures, and optimize production processes—all in real-time from a single dashboard.
Temperature, vibration, acoustic, and pressure sensors with edge computing for real-time processing
Time-series anomaly detection, predictive failure models, and classification algorithms trained on your data
OPC-UA, MQTT, Modbus connectors to existing SCADA/PLC systems. Works with legacy equipment
Detect bearing failures, misalignment, and imbalance before they cause catastrophic equipment failure
Identify electrical and mechanical issues through heat signature analysis and thermal patterns
Pre-trained ML models for common manufacturing equipment failures accelerate deployment
Monitor quality metrics in real-time to maintain consistent product quality and reduce defects
Detect abnormal sounds indicating equipment problems using advanced audio analysis
Combine multiple data sources for highly accurate predictions and comprehensive equipment insights
Predict exactly how long equipment will last to optimize maintenance schedules and budgets
Automated correlation of failures with operating conditions to identify true root causes
ISO 9001 quality management support • CE marking compliance • Health & safety integration • Complete audit trail documentation • GDPR-compliant data handling
What happens: Factory walkthrough. Equipment audit. Data availability review.
Your involvement: Tour facility with our engineers. Provide maintenance records and equipment specs.
Deliverable: Detailed assessment report with ROI projections and implementation roadmap.
What happens: Install sensors on 1-3 critical machines. Begin data collection and model training.
Your involvement: Coordinate installation during maintenance windows. Provide historical failure data.
Deliverable: Pilot dashboard with predictive alerts for test equipment.
What happens: Fine-tune prediction models. Validate against your production environment.
Your involvement: Verify alerts match real conditions. Provide feedback on accuracy.
Deliverable: Calibrated system with proven prediction accuracy (>85%).
What happens: Expand to all critical equipment. Integrate with maintenance management system.
Your involvement: Coordinate installation schedule. Update maintenance procedures.
Deliverable: Fully deployed system monitoring entire production line.
What happens: Train maintenance team, production managers, and operators.
Your involvement: Attend training sessions. Practice using dashboards and responding to alerts.
Deliverable: Trained team with standard operating procedures.
What happens: Continuous model improvement. Monthly performance reviews. 24/7 system monitoring.
Your involvement: Monthly review meeting. Report system performance.
Deliverable: Ongoing improvements, updates, and guaranteed uptime.
Irish manufacturers trust us to reduce downtime and optimize operations. Here's how we've helped businesses like yours.
FMCG Manufacturing • 85 Employees
Computer vision quality control caught defects before packaging, reducing waste and customer complaints
Electronics Assembly • 150 Employees
Real-time production analytics identified bottlenecks and optimized line balancing across 4 production lines
Injection Molding • 65 Employees
Demand forecasting and supply chain optimization reduced raw material inventory by 35%
We'll analyze your production environment and show you exactly where predictive maintenance can reduce costs and improve reliability—with no obligation.
Irish manufacturer with 20-250 employees looking to scale operations
Experiencing frequent unplanned downtime eating into productivity and profits
Reactive maintenance and emergency repairs cutting into your margins
Real answers from our experience working with Irish manufacturers. Don't see your question? Get in touch.
Yes. Our IoT sensors work with equipment from any decade. We've successfully deployed on machines from the 1980s through today. No need to replace functional equipment—we make what you have smarter.
Minimal disruption. Sensor installation takes 1-3 hours per machine during scheduled maintenance. We pilot test on non-critical equipment first, then full deployment is coordinated around your production schedule.
After a calibration period of 6-8 weeks, accuracy typically exceeds 85% for critical failures. Accuracy improves over time as models learn from your specific equipment and operating conditions.
Most Irish manufacturing SMBs invest €25K-€75K for initial implementation (sensors + software + integration), with €1.5K-€4K/month for support and cloud hosting. Exact pricing depends on number and type of machines. We'll provide detailed pricing in your free assessment.
Typical implementation is 4-6 weeks from assessment to full deployment. This includes sensor installation, data integration, model training, team training, and testing. We work around your schedule to minimize impact.
Not at all. Our dashboards are designed for production managers and maintenance teams, not data scientists. We provide full training and ongoing support. If your team can use a smartphone, they can use our tools.
Every manufacturing facility is unique. Get personalized answers during your free assessment.
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