Edge Devices & IIoT Integration:

• Digi-Arc designs architectures that connect factory assets (PLCs, sensors, machines) to IIoT platforms.
• Use edge computing to process data locally, reducing latency and enabling real-time insights.

Data Pipelines & Visualization:

• Implement data pipelines that extract, transform, and load (ETL) shop floor data into centralized data lakes or cloud platforms.
• Enable real-time dashboards and visualizations using Power BI, Tableau, or Grafana.

Predictive Maintenance & Anomaly Detection:

• Leverage machine learning algorithms to predict equipment failures and optimize maintenance schedules.
• Use anomaly detection techniques to identify deviations in production quality.

Example:

On a pharma factory floor, real-time monitoring of temperature, humidity, and batch deviations ensures compliance with GMP standards.

MES (Manufacturing Execution System) Integration:

• Digi-Arc designs solutions that connect MES with ERP systems (SAP, Oracle) and warehouse systems (WES/eWM) for synchronized production planning.
• Enable real-time work-in-progress (WIP) tracking and automated production scheduling.

Low-Code/No-Code Platforms for Shop Floor Apps:

• Use platforms like Tulip, Plex, or Siemens Mendix to build custom apps for operators and supervisors.
• Apps streamline tasks such as quality checks, maintenance logging, and downtime reporting.

ERP-Driven Material Management:

• Real-time inventory and material flow visibility using ERP integration reduces downtime and optimizes production planning.

Example:

In a discrete manufacturing plant, MES-ERP integration ensures real-time production scheduling and automated lot tracking.

Digital Twins for Asset Monitoring:

• Architects build digital twins of production lines or critical assets, simulating operations and predicting potential failures.
• Use IoT data streams to keep the twin synchronized with physical equipment.

Connected Maintenance Workflows:

• Integrate CMMS (Computerized Maintenance Management Systems) with MES and ERP.
• Automate maintenance work orders based on real-time asset conditions (e.g., vibration thresholds or thermal anomalies).

Example:

In an automotive plant, vibration sensors on stamping machines trigger automated service tickets when thresholds are exceeded.

Augmented Reality (AR) for Field Service:

• Digi-Arc designs AR solutions for remote diagnostics and guided maintenance.
• Field technicians use HoloLens or mobile AR apps to access real-time service manuals, schematics, and expert assistance.

Remote Monitoring & Service Portals:

• Deploy customer portals for service visibility, allowing clients to track asset conditions, request services, and monitor SLAs.

IoT-Powered Service Models:

• Architects enable IoT-powered predictive service models, reducing unplanned downtime through remote monitoring and preemptive part shipments.

Example:

In an industrial equipment plant, AR-guided maintenance reduces service times by 30%.

Cloud-Native Architectures:

• Design scalable platforms on AWS, Azure, or Google Cloud to store and process large volumes of factory data.
• Use API gateways and microservices for seamless integration with existing systems.

Edge Computing for Low-Latency Needs:

• Deploy edge devices to process machine data locally, reducing the need for constant cloud connectivity.
• Use MQTT or OPC UA protocols to stream relevant data to cloud platforms for further analysis.

Example:

In a pharmaceutical factory, edge devices process GMP-compliant sensor data locally to prevent latency issues.

Secure Factory Networks:

• Digi-Arc implements zero-trust architectures to protect OT and IT networks.
• Use role-based access control (RBAC) and network segmentation to prevent unauthorized access.

Compliance with Industry Standards:

• Ensure systems align with ISO 27001, NIST, and GxP requirements.
• Regular audit trails and logs for compliance verification.

Example:

In a medical device plant, adherence to 21 CFR Part 11 ensures secure data logging and traceability.