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AIPLANT4.0 · Intelligent Manufacturing Platform

Connect Every Machine. Predict Every Outcomes. Save Money and Time.

Phygitalz is an AI and Industry 4.0 company transforming factories through IIOT, Agentic AI, Digitla Twin, Digital Thread and smart manufacturing solutions. We help manufacturers build smarter, more efficient, highly effective and future-ready factories with predictive capabilities across function in your factories

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AIPLANT4.0 is built by PHYGITALZ: all your manufacturing solutions under one AI platform

PLATFORM OVERVIEW

Why Customers Choose
Phygitalz's AI Plant4.0?

AI Plant4.0 is the factory of the future, with top 12 shop floor solutions interconnected with each other on a unified AI Platform with AI Agents, Digital Twin, Digital Thread and IIOT Technologies.
AI Plant4.0 Platform is Successfully running at INDIAN Defence Factories, Commercial Vechicle OEM, TVS and JAPANESE Companies for the last 7years.
AI Plant4.0 is highly configurable and coustomizable to every customer specfic needs.
AI Plant4.0 is a Defence Grade Platform tested and proven for vulnerability and penetration testing.
AI Plant4.0 is faster to configure and reach ROI within 3 to 6 months

AIPLANT4.0 Solutions

Everything your plant needs to see, predict and improve

Every solution below is part of AIPLANT4.0, the platform PHYGITALZ built to connect your machines, people and processes. Start with the outcome you need most and add more on the same platform as you grow.

  1. OEE 4.0Overall Equipment Effectiveness monitoring and it is the product of Availability, Performance and Quality. Shows the Actual Performance of the Shop floor and Losses can be captured second by second. Learn more
  2. Digital Plant Maintenance (CMMS)Connected digital plant maintenance covering breakdown, preventive maintenance, RCA and maintenance expense. Learn more
  3. Quality 4.0Zero-defect quality with SPC variable/attribute measurement, control charts and AI-based special-cause detection. Learn more
  4. Energy 4.0Real-time electricity, water, gas and air consumption monitoring with cost-per-part and tariff management. Learn more
  5. Condition MonitoringCondition monitoring and predictive maintenance with abnormal condition alerts and spare-parts demand prediction. Learn more
  6. Digital FactoryDigital drawings, work instructions, control plans and process flow diagrams for every part. Learn more
  7. Traceability 4.0End-to-end digital thread from product to sub-assembly to component, process, quality and asset condition. Learn more
  8. Tool Life MonitoringTool store and tool life management with live tracking, reground history and trade-off analytics. Learn more
  9. Inventory & Spares ManagementInventory and spares part master, location management, inward/outward tracking integrated with maintenance. Learn more
  10. Calibration 4.0Calibration master, schedule, certifications, alerts and dashboard for instrument calibration management. Learn more
  11. ERP InterfaceProduction order, job card and scheduling management integrated with ERP. Learn more
  12. Auto BalooningExtracts CTQ from 2D Drawings from PDF Files to Excel Learn more
  13. LeadsCapture, organise and follow up every lead in one place, from first enquiry to handover, with stages, notes and team assignment. Learn more
  14. PipelineTrack every opportunity on a pipeline board, move leads between stages as they progress, and see the whole pipeline at a glance. Learn more
  15. ProposalsBuild branded proposals from templates and a shared catalogue, price them consistently and keep track of them from one dashboard. Learn more
  16. Subscription ManagementLet clients choose a plan, manage their subscriptions and pay, while your team handles renewals, direct purchases and billing in one place. Learn more
  17. Lead FinderFind potential customers, review what turns up, approve what is worth pursuing and keep the follow-up tasks in one place. Learn more
  18. OutreachMessage your leads and customers from one place, with broadcasts to many at once and email templates for the messages you send often. Learn more
  19. Customer SupportGive clients one place to raise a ticket and follow the conversation, and give your team a clear list of what needs a reply. Learn more
  20. MarketingTrack marketing results, build landing pages and keep a knowledge base your team can rely on. Learn more
  21. Govt TendersKeep track of government tenders that match what you sell, and follow each bid in one place. Learn more
  22. Conferences and EventsPlan and follow your conferences and events, with dashboards for what is booked and what is coming up. Learn more
  23. AttendancePunch in and out, see every employee's daily and monthly attendance, and keep the holiday calendar in one place. Learn more
  24. Leave and PermissionLeave and permission requests with approval, leave policies and accrual, balance adjustment and settlement. Learn more
  25. PayrollConfigurable salary structures, formula-based calculation and monthly payroll runs linked to attendance. Learn more
  26. Work RulesWeekly-off rules and policies, working-hours rules and work-from-home rules per employee. Learn more
  27. Payslips and ReportsPayslips as PDF or email, the payroll register, the NEFT bank report and Excel export. Learn more
  28. Payroll SecurityEncrypted salary data with employee and authority keys, and key rotation. Learn more
  29. Employee Self-ServiceEmployees see their own salary profile, payslips and attendance and raise leave and permission requests. Learn more
  30. HR AdministrationLogin, role-based access control, user configuration and your organisation, site and department structure. Learn more
  31. Purchase RequestPurchase requests raised by designated requesters, by site, optional store and purchase type. Learn more
  32. QuotationRecord vendor quotations against a purchase request. Learn more
  33. Purchase OrderCreate purchase orders from a request or quotation, or enter them manually, with PO PDF. Learn more
  34. Purchase InvoiceRecord the vendor's invoice against a purchase order and track payment. Learn more
  35. Purchase ReturnReturn goods to the vendor and keep the record. Learn more
  36. Delivery ChallanCreate and track delivery challans. Learn more
  37. Purchase LedgerA vendor-wise purchase ledger with a ledger PDF. Learn more
  38. Purchase SettingsDocument numbering, purchase types and user signatures for your purchase documents. Learn more
  39. Item MasterYour item catalogue: groups, types and specifications, images, bulk upload and numbering. Learn more
  40. Item InwardRecord goods received. Learn more
  41. InventorySee your stock and search it. Learn more
  42. Item RequestRaise internal requests for items from stock. Learn more
  43. Vendor ManagementVendor and vendor-type master, bank details, and Excel and PDF export. Learn more
  44. SCM AdministrationLogin, role-based access control, user configuration and your site and store structure. Learn more
  45. Finance (Basic)Vendor payments through purchase invoices and the purchase ledger, with company expenses coming soon. Learn more
  46. CollaborationTask management and customer issue management for your teams. Learn more
  47. PlatformThe shared foundation of the ERP: single login, access by role, users and your organisation structure. Learn more
  48. General LedgerComing soon: your chart of accounts, journal entries and financial statements. Learn more
  49. Accounts ReceivableComing soon: customer invoices, receipts and collections, and customer ledgers. Learn more
  50. SalesComing soon: sales quotations, sales orders, delivery and invoicing. Learn more
View all solutions
WHO WE SERVE

Industries Served

One intelligent platform, adapting to every manufacturing environment — a living ecosystem of connected smart factories.

  • Production Line
  • Engine Manufacturing
  • Transmission
  • Assembly
  • AI Monitoring
  • Predictive Maintenance
  • Quality
  • Energy
  • IoT Dashboard
  • Heavy Equipment
  • Machine Health
  • Fleet Monitoring
  • Predictive Maintenance
  • OEE
  • Digital Twin
  • AI Models
  • Asset Tracking
7+Years of Innovation
25%Increase in Productivity
99.5%Platform Availability
30%Average Downtime Reduction
24/7Real-Time AI Monitoring
98%Customer Retention

CUSTOMER VOICES

What Our Customers Say

Phygitalz implemented Tool Life Management and Digital Traceability solutions for one of our cells having both robotic and manual operations. Their unique expertise in digital technology and interfacing with CNC machines, FANUC data acquisition software and RFID sensors helped us establish real-time tool life visibility and digital traceability from component to cell, operation, machine and pallet level. The team spent significant time understanding our requirements and delivered a solution that worked out very well for us.

Senior General ManagerIndian Large Automotive Tier-1

UNDER THE HOOD

Technology Stack

Machine Integration

Siemens CNCDirect data acquisition from Siemens CNC controllers.
Fanuc CNCDirect data acquisition from Fanuc CNC controllers.
MitsubishiMitsubishi PLC and CNC connectivity.
Conventional MachinesRetrofit sensors bring legacy, non-networked machines online.
SCADASCADA system bridging for plant-wide visibility.
RobotsRobotic cell monitoring and cycle tracking.
PressPress tonnage, cycle and stroke monitoring.
SPMSpecial purpose machine integration.
ModbusModbus RTU/TCP protocol for industrial device communication.
MQTTLightweight MQTT messaging for IIoT telemetry.
OPC UAOPC UA for secure, vendor-neutral machine data exchange.

Platform & Security

Angular FrameworkModern, responsive front-end built on Angular.
Python DjangoSecure, scalable back-end built on Python Django.
AES 256 EncryptionIndustry-standard AES-256 encryption for data at rest and in transit.
Authentication EngineRole-based authentication for every user and session.
Access Control EngineGranular, role-based access control across the platform.
SSL CertificateEnd-to-end HTTPS/SSL encrypted connections.
Windows ServerEnterprise-grade hosting on Windows Server.
SQL ServerMicrosoft SQL Server for reliable, scalable data storage.

Sensors & IoT

VFDVariable frequency drive signal capture for motor load and speed.
TransducerPressure and force transducers for process monitoring.
Dynamo/RPM SensorRPM sensing for spindle and motor speed tracking.
Flow SensorCoolant, air and fluid flow monitoring.
Energy SensorReal-time electricity, water, gas and air consumption monitoring.
BluetoothWireless short-range sensor connectivity.
QR SensorQR-code based part and asset identification.
RFIDRFID tagging for part, tool and pallet traceability.
CameraMachine vision for quality inspection and monitoring.
GPSGPS location tracking for mobile assets.
CMMCoordinate measuring machine data for dimensional quality.
LabVIEWLabVIEW-based test and measurement integration.
GET STARTED

Ready to get connected?

See how AIPlant4.0 can reduce downtime, cut maintenance expense and give you real-time visibility across every machine and every second.

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