TECHAIVVTechnology. Process. People.
Talk to Us

Manufacturing

Connect the Plant. Run on Real-Time Data.

We help discrete, process and contract manufacturers connect shop-floor, quality, maintenance and enterprise systems. Production is visible as it happens, quality is traceable, and AI goes where it prevents downtime, with engineers making the final call.

Talk to UsWays to Start
Most plants already have the data. It’s stuck in machines, spreadsheets and systems that don’t talk. Smart manufacturing starts with connecting what you run today, not with buying a new factory.
Our point of view
Machine operator smiling beside production equipment on a factory floor

25%India’s target share of GDP from manufacturing

11%of revenue large manufacturers lose to unplanned downtime

Manufacturing Now

India Is Scaling Manufacturing. Plants Must Get Smarter.

Policy support, new capacity and rising cost pressure are changing how manufacturers plan, produce and compete.

Strategic Priorities

The Problems Manufacturing Leaders Bring to Us

Six recurring issues we hear from plant, operations, quality and technology leaders. Each one maps to the capabilities further down this page.

  • P01

    No Real-Time Shop-Floor Visibility

    Production status is collected by hand at the end of a shift.

    We often hear“We see yesterday’s problems today.”

  • P02

    Disconnected IT and OT

    Machines, MES, SCADA and ERP run as separate worlds.

    We often hear“The ERP doesn’t know what the line actually made.”

  • P03

    Unplanned Downtime

    Equipment fails without warning, and maintenance is reactive.

    We often hear“We fix machines after they stop.”

  • P04

    Quality Found Too Late

    Defects are caught at final inspection, not at the source.

    We often hear“By the time we spot the defect, the batch is done.”

  • P05

    Paper-Based Operations

    Work instructions, checklists and logs are still on paper.

    We often hear“Our audit trail is a filing cabinet.”

  • P06

    Planning That Can’t Keep Up

    Production plans don’t adjust to demand, material or capacity changes.

    We often hear“Every schedule change means a day of spreadsheets.”

Segments

Who We Work With in Manufacturing

Each type of plant produces, measures and is regulated differently. We shape the work to fit.

  • Technician wiring an automotive component on an assembly line

    Discrete Manufacturing

    Automotive, auto components, industrial equipment, electronics

    Connect lines, machines and ERP for live output, OEE and traceability.

    • Plant Head
    • Manufacturing IT
    • Production Manager
  • Bottled drinks moving along a production conveyor

    Process Manufacturing

    Chemicals, FMCG, food & beverage, pharma

    Digitise batches, quality checks and process data for consistency and compliance.

    • Operations Head
    • Quality Head
    • Process Engineering
  • Technician assembling circuit boards on a workbench

    Contract Manufacturers & EMS

    Contract manufacturing, electronics manufacturing services

    Run multi-customer production with clear traceability and reporting.

    • COO
    • Programme Manager
    • IT Director
  • Worker walking through a metal fabrication plant

    Industrial & Engineering Firms

    Heavy engineering, capital goods, fabrication

    Connect projects, production, assets and service for complex, made-to-order work.

    • CEO
    • Engineering Head
    • After-Sales Service

Value Chain & Use Cases

Where We Help Across the Manufacturing Value Chain

Use cases we deliver at each stage, tagged by the capability behind them.

  1. Design & Engineering

    • PLM and ERP integration for product dataIntegration
    • Engineering document search and change trackingAI

  2. Plan

    • Production planning and scheduling dashboardsData
    • Demand and material forecastingAI

  3. Produce

    • Machine connectivity (IIoT) and live OEE dashboardsData
    • MES, SCADA and ERP integrationIntegration

  4. Quality

    • Digital checklists, deviations and CAPA workflowsAutomation
    • Vision-based defect detectionAI

  5. Maintain

    • Predictive maintenance from sensor dataAI
    • CMMS work orders and spares workflowsAutomation

  6. Ship & Serve

    • Batch and serial traceabilityData
    • Dealer and field service portalsEngineering

Sample Engagements

What Working With Us Could Look Like

Typical projects based on the problems above, with what we would measure.

Operator checking a machine control screenIllustrative engagement

Discrete

Live OEE and Shop-Floor Visibility

Situation
Output, downtime and scrap are logged by hand each shift, so problems surface a day late.
What we would do
Connect machines and MES to a data platform, and build live OEE and downtime dashboards with reason codes and shift-wise alerts.
  • HigherOEE (target)
  • Fasterresponse to stoppages

Capabilities

Capabilities Mapped to Your Priorities

See which of our practices answers each priority, so you know where to start.

  • Application Engineering

    Operator apps, portals, APIs

    1. No Real-Time Shop-Floor Visibility: not a main fit
    2. Disconnected IT and OT: not a main fit
    3. Unplanned Downtime: not a main fit
    4. Quality Found Too Late: not a main fit
    5. Paper-Based Operations: primary fit
    6. Planning That Can’t Keep Up: not a main fit

  • AI & Intelligent Automation

    Predictive maintenance, vision, forecasting

    1. No Real-Time Shop-Floor Visibility: not a main fit
    2. Disconnected IT and OT: not a main fit
    3. Unplanned Downtime: primary fit
    4. Quality Found Too Late: primary fit
    5. Paper-Based Operations: not a main fit
    6. Planning That Can’t Keep Up: supporting

  • Data Engineering & Analytics

    IIoT data, OEE, traceability

    1. No Real-Time Shop-Floor Visibility: primary fit
    2. Disconnected IT and OT: supporting
    3. Unplanned Downtime: supporting
    4. Quality Found Too Late: supporting
    5. Paper-Based Operations: not a main fit
    6. Planning That Can’t Keep Up: primary fit

  • Integration & Workflow Automation

    MES, SCADA, ERP, CMMS, PLM

    1. No Real-Time Shop-Floor Visibility: supporting
    2. Disconnected IT and OT: primary fit
    3. Unplanned Downtime: supporting
    4. Quality Found Too Late: not a main fit
    5. Paper-Based Operations: supporting
    6. Planning That Can’t Keep Up: supporting

  • Cloud, DevOps & Platforms

    Edge-to-cloud, scalable, monitored

    1. No Real-Time Shop-Floor Visibility: supporting
    2. Disconnected IT and OT: supporting
    3. Unplanned Downtime: not a main fit
    4. Quality Found Too Late: not a main fit
    5. Paper-Based Operations: not a main fit
    6. Planning That Can’t Keep Up: not a main fit

  • Secure & Governed Design

    OT security, access control, audit trails

    1. No Real-Time Shop-Floor Visibility: not a main fit
    2. Disconnected IT and OT: supporting
    3. Unplanned Downtime: not a main fit
    4. Quality Found Too Late: supporting
    5. Paper-Based Operations: supporting
    6. Planning That Can’t Keep Up: not a main fit
  1. P01 No Real-Time Shop-Floor Visibility
  2. P02 Disconnected IT and OT
  3. P03 Unplanned Downtime
  4. P04 Quality Found Too Late
  5. P05 Paper-Based Operations
  6. P06 Planning That Can’t Keep Up

How We Work

Five Steps From Challenge to Measurable Result

Plant changes are scheduled around production windows and follow your safety and change-control procedures.

Discuss Your Manufacturing Priorities

  1. Discover the Challenge

    Walk the floor and map machines, systems, data, people and where losses happen.

  2. Define Scope & Measures

    Agree use cases, deliverables, baselines and the metrics that matter, such as OEE, downtime, scrap and first-pass yield.

  3. Design With Controls

    Plan architecture, IT/OT integration, OT security, access controls and human review.

  4. Build & Test

    Develop the solution and test it on a pilot line or asset against agreed acceptance criteria.

  5. Roll Out & Improve

    Scale line by line and plant by plant, monitor results and keep improving.

FAQs

Questions Manufacturing Teams Ask Us

Still have a question?

Talk to us about your plants, systems and goals.

Talk to Us
Can TECHAIVV connect our machines, MES and ERP?

Yes, through industrial protocols (such as OPC UA and MQTT), APIs and middleware. What’s possible depends on machine age, controllers, network setup, access permissions and your OT security policies.

Do we need new machines to become a smart factory?

No. Older machines can often be connected with sensors and edge devices. We recommend new equipment only when existing assets truly limit the result.

How do you keep plant systems secure when connecting IT and OT?

We design for network separation, least-privilege access, monitoring and secure data flows, aligned with standards such as ISA/IEC 62443 and your own policies. Security is agreed with your plant and IT teams up front.

Will AI and predictive maintenance work on our data?

It depends on data history, sensor coverage and failure patterns. We start with a pilot on critical assets, measure it against a baseline, and scale only what proves useful.

How do we get started?

With a short discovery of your plants, systems and priorities. Then we agree one use case on one line or asset, plus its measures, and deliver that first.

Let’s Build Together

Build a Plant That Runs on Real-Time Data

Connect your machines and systems, see production as it happens, and put AI where it prevents downtime and defects.

Talk to Us
  • Connected Shop Floor
  • Live Production Data
  • Predictive Maintenance
  • Traceable Quality