FMCG
A tailor-made industrial application across sales, production and quality, with AI recommending refining parameters and predicting defects before scrap: 30% faster process time.
Digital Manufacturing
Digital manufacturing solutions with proven results:
up to 15% higher OEE, 25% fewer unplanned downtimes, 30% lower energy costs.
Explore 13 use cases
Trusted by
What is digital manufacturing?
Digital manufacturing is the use of connected machine data, industrial software and AI to monitor, analyse and optimise production in real time - production monitoring with OEE, predictive maintenance, energy management, paperless workflows and AI-driven optimisation, built on a common data foundation such as a unified namespace. Decisions are based on live data instead of paper reports and intuition.
92%+
see smart manufacturing as the key driver of competitiveness
80%
invest over a fifth of improvement budgets in it
65%
cite operational risk as their top concern
Deloitte Smart Manufacturing Survey 2025, n=600 executives.
What is blocking your digital transformation?
Pick your role and one or more problems. Every use case below comes from real deployments and links to a detailed solution page.
Recommended start: Industry 4.0 Quick Scan → a measurable PoC on one line in 8–12 weeks.
Showing all use cases. Select a problem on the left to narrow them down and see why each one fits.
AI
Deviation & Reconciliation
Recipe drift caught before it becomes scrap · plan vs reality reconciled
Digital Work Instructions
Faster onboarding · automatic distribution of instructions
AI
Process Optimisation with AI
Less raw material waste · stable processes without expert supervision
Estimate improvement potential in 60 seconds
Pick the area, enter numbers you already know from your own cost base. Ranges come from results measured in TT PSC deployments - assumptions shown with every result.
Estimated annual savings potential
Conservative€72,000
Typical€129,600
Optimistic€180,000
Savings = your annual downtime cost × 10–25% downtime reduction measured in TT PSC OEE deployments (up to ~25% in year one).
Get the full breakdown with per-category savings, assumptions and a recommended starting point.
From problem to investment decision
Wherever you are today - paper reports or AI pilots - the path starts the same way: a low entry threshold instead of a large programme. KPIs are defined before the project starts, so the PoC either proves value or saves you the investment.
Not sure where to start?
A free consultation with our Industry 4.0 experts gives you an honest assessment of where digital solutions deliver the most value.
Success Stories
Each story comes from a different use case, so you can see how the same data foundation solves very different production problems.
Electric buses / Europe
AR remote service and digital work instructions on RealWear industrial glasses. Technicians at Europe's leading electric bus manufacturer stream their view to central experts in real time, follow instructions hands-free and document repairs as they work.
- Faster diagnostics
- Fewer service trips
- Minimised bus downtime
References
Own your factory's intelligence
Own the brain, don't rent it. TT PSC is a solutions integrator, not a software vendor: we connect OT and IT end to end, and what we build stays yours.
1200+
projects delivered globally
25+
years in industrial software
8-12
weeks to a measurable PoC
Our partners
One architecture for OT, IT, AI and operational decisions
Every use case above runs on the same layered foundation, so each new initiative reuses the connectivity and data work of the previous one instead of starting from scratch.
Industrial connectivity
Machines, PLCs and legacy protocols connected through Kepware industrial connectivity, OPC UA and MQTT, from the shop floor to the edge.
Unified namespace
A unified namespace decouples data producers from consumers and gives SCADA, MES and historian data a shared real-time context.
Analytics and AI
Industrial analytics, predictive models and AI agents that detect anomalies, predict failures and recommend process parameters.
Applications and people
OEE dashboards, digital work instructions, energy and quality applications delivered to operators, engineers and managers on any device.
AI for Manufacturing
AI that works on the shop floor, not in slides
Under pressure to show AI results without a multi-year IT programme? AI initiatives fail on data, not on models, so every TT PSC AI engagement has to prove itself on live machine data. And it stays defensible: every recommendation traces back to the data and the rule behind it, so you can prove why, not just trust it. Here is what that looks like at scale:
Case study
AI process optimisation
One AI optimisation engine, rolled out to 9 factories
At a global tobacco manufacturer, our models read process parameters straight from PLCs and apply optimal settings directly in the process. Result: stable output, less raw material waste, scaled from one plant to nine.
Drying, blending, combustion, thermal treatment: the same physics runs in food & beverage, chemicals and building materials; the models transfer. Optimisation is one application; predictive maintenance, quality and energy models live in the Navigator above.
9 factories
running the solution in production
Live PLC data
models work on machine data, not spreadsheet exports
Closed control loop
optimal settings flow back into the process, not into reports
Your factory, our technology
Download the Practical Guide to Industry 4.0 with 13 detailed use cases and results, or talk to us about where to start in your plant.
You will talk to:
Jakub Kaczyński
Industrial Portfolio Director
FAQ
Digital transformation is a broad process of using digital technologies to reshape how a business operates, delivers value, and interacts with customers. Digital manufacturing focuses specifically on transforming the manufacturing process.
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