Industries

Manufacturing Intelligence

Modernise factories with AI that predicts downtime, optimises throughput, and empowers teams with real-time insights from the edge to the cloud.

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Transformation focus

  • Predictive maintenance and asset performance
  • Digital twins for production planning
  • Worker safety analytics and augmented assistance

Connected operations

IoT data integration, MES interoperability, and cloud historian platforms unify the shop floor.

Quality excellence

Computer vision, anomaly detection, and SPC dashboards deliver first-pass yield improvements.

Sustainable operations

Energy monitoring, ESG reporting, and optimisation models minimise waste and emissions.

Modern factory roadmap

  • InstrumentationSensor strategy, data acquisition, and connectivity across legacy and new assets.
  • InsightEdge analytics, dashboards, and AI-assisted decision support for plant teams.
  • InnovationClosed-loop optimisation with prescriptive maintenance and autonomous adjustments.

Technology ecosystem

  • Azure IoT, AWS IoT, Siemens, PTC ThingWorx
  • Grafana, Power BI, Tableau for manufacturing analytics
  • Edge compute with NVIDIA, Advantech, and rugged devices

Create resilient, data-driven manufacturing operations with Nexora’s industrial specialists.

Smart Factory

IoT Production Dashboard

Real-time equipment monitoring, predictive maintenance alerts, and production optimization insights.

Manufacturing AI Solutions

  • Predictive maintenance and anomaly detection
  • Computer vision quality inspection
  • Digital twin simulation and optimization
  • Collaborative robotics and automation
Smart Operations

Connected production ecosystem

From raw materials to finished goods, optimize every step with IoT sensors, AI analytics, and automated decision-making for maximum efficiency and quality.

Asset Performance

Monitor equipment health in real-time, predict failures before they occur, and optimize maintenance schedules.

Quality Control

AI-powered visual inspection detects defects with 99%+ accuracy, reducing waste and rework.

Supply Chain Optimization

Demand forecasting, inventory optimization, and automated procurement to minimize disruptions.

Production Line Flow

Material Intake

IoT Sensors RFID Tracking Automated Sorting

Sensor: ActiveTemp: 22C
Assembly

Robotic Arms Vision QC Torque Monitoring

Status: Running
Quality Check

AI Vision Defect Detection X-Ray Scan

Accuracy: 99.4%
Packaging and Dispatch

Auto Packaging Labeling Warehouse Integration

1,247 Units TodayOEE: 87%

Real-Time Metrics

94%
Uptime
2.3x
Throughput
18%
Cost savings

Smart Manufacturing Capabilities

Predictive Maintenance

ML models analyze sensor data to predict equipment failures 2-3 weeks in advance, reducing downtime by 40%.

Quality Assurance

Computer vision systems inspect products at line speed with 99.5% accuracy, catching defects humans miss.

Digital Twin

Virtual replicas of production lines enable what-if analysis and optimization before physical changes.

Worker Assistance

AR guidance, safety monitoring, and automated documentation improve productivity and reduce errors.

Siemens Rockwell GE Digital SAP PTC ThingWorx

Manufacturing Use Cases

Automotive

Assembly line optimization, weld quality inspection, and predictive maintenance for CNC machines.

Pharmaceuticals

Batch quality control, contamination detection, and regulatory compliance automation.

Electronics

PCB defect detection, component placement verification, and yield optimization.

Food and Beverage

Quality inspection, contamination detection, and production optimization for FMCG.

Frequently asked questions

Our ML models analyze vibration, temperature, and other sensor data to detect anomalies 2-3 weeks before failure. This allows scheduled maintenance during planned downtime, reducing unplanned outages by 35-45%.

Clients typically see 60-80% reduction in defect escape rates, 30-40% decrease in inspection costs, and 20-25% improvement in yield. ROI is usually achieved within 6-9 months.

No, our solutions integrate with existing PLCs, SCADA systems, and equipment via IoT sensors and edge gateways. We support brownfield deployments and gradual migration paths.

Operational Impact

42%

Reduction in downtime

35%

Increase in productivity

99.5%

Quality inspection accuracy

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