Machine
CNC · Live sensors
- Tool Life83%
- Productivity92%
- Downtime0%
- Spindle Load74%
- Coolant PressureOK
- VibrationNormal
The Flow
Four stages, one platform
1
Connect
Machines, sensors & PLCs stream data through the IoT gateway.
2
Monitor
Live dashboards track every asset across sites and shifts.
3
Analyze
AI/ML models turn raw signals into predictions and alerts.
4
Act
Teams act before problems happen — less downtime, more output.
Digital Thread
Shop Floor to Top Floor
Machine sensor data flows through an IoT Gateway into the AIPLANT4.0 Core, where AI models turn raw signals into predictions your team can act on before problems happen.
IoT Gateway
Edge Connectivity
Transmitting · 2.4k msg/s
AIPLANT4.0 Core
Edge Server · AI Inference
- Model Accuracy98.6%
- GPU Usage61%
- Live Inference2.4k/s
AI Predictions
Real-time foresight
- Tool Life Remaining128 hrs98%
- Bearing Failure RiskLow96%
- Energy Optimization+14%
- Production Forecast1,258 units
- Next Maintenance3 days
- OEE Prediction92.4%94%
The path every PHYGITALZ deployment follows
The same repeatable steps, from understanding your plant to acting on its data.
Understand Plant
Map every machine, process and data source across the shop floor.
Connect Machines
Integrate PLCs, sensors and legacy equipment through the IoT Gateway.
Collect Data
Stream live production, quality and machine-health data into one platform.
AI Analysis
Apply predictive models to detect patterns, risks and inefficiencies.
Recommendations
Turn AI insight into specific, actionable operational recommendations.
Continuous Improvement
Track outcomes and refine models as the plant evolves.