Machine
CNC · Live sensors
- Tool Life83%
- Productivity92%
- Downtime0%
- Spindle Load74%
- Coolant PressureOK
- VibrationNormal
Digital Twin — Live
Connect Every Machine. Predict Every Outcomes. Save Money and Time.
Phygitalz is an AI and Industry 4.0 company transforming factories through connected machines, intelligent automation, real-time data, and smart manufacturing solutions. We help manufacturers build smarter, more efficient, and future-ready factories.
PLATFORM OVERVIEW
What is AIPlant4.0?
AIPlant4.0 unifies machine monitoring, quality, maintenance, energy, tooling and traceability into one connected digital platform — giving manufacturing teams a single source of truth from shop floor to top floor, built on a common master-data foundation and AI/ML models.
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%
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
5+Years of Innovation
25%Increase in Productivity
99.5%Platform Availability
30%Average Downtime Reduction
24/7Real-Time AI Monitoring
98%Customer Retention
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.