top of page
  • AutorenbildRalf Pühler

Digital Manufacturing Optimization

Aktualisiert: 11. Jan. 2022

Leveraging the Industrial Internet of Things (IIoT): Industrial IoT and AI-based optimization solutions for advanced manufacturing provide intelligent insights that empower manufacturers to make optimized decisions in real-time, every time. Seamless integration of existing data sources help you increase material utilization, improve productivity, quality and quality control.

With the use of innovative IoT modules, manufacturers can achieve a higher OEE, reduce costs and improve other KPIs relevant to the production environment.

Due to the continuously advancing globalization of the world economy and a greater degree of networking of the value-added processes, the alignment of optimal production is becoming increasingly strategic. For a sustainable design of production systems, a large number of production management questions have to be examined. Because the successful implementation of almost all known competitive strategies are essentially based on the effectiveness of production.

At the level of the functional strategies, production strategies are therefore to be pursued which, in coordination with the respective targeted competition strategy, force a strategic alignment of production.

In the real environment, instead, there is often a focus on (general) strategic production management and on instruments for increasing productivity and reducing costs, e.g. just-in-time, lean production and total quality management.

Cheaper, more powerful and more flexible technologies accelerate the growth of fully automated production systems. The main challenge for companies will be to decide how they can best use their potential applications.

Automation systems are becoming more and more flexible and intelligent and automatically adapt their behavior to maximize performance or minimize the cost per unit. Expert systems used in beverage filling and packaging lines can automatically adjust the speed of the entire production line to the activity that is the critical limitation for a given batch. In automotive manufacturing, expert systems can automatically make minor line speed adjustments to improve the overall balance of individual lines and maximize the effectiveness of the entire manufacturing system.

While the vast majority of robots in use today are still operating in high-speed and mass-production applications, the most advanced systems can make adjustments on the fly and seamlessly switch between product types without stopping the line to change programs or reconfigure tools. Many current and emerging production technologies, from Computerized Numerical Control (CNC) cutting to 3D printing,

The automation strategy must be aligned with the business and operational strategy. As mentioned above, automation can achieve four main goals: improving work safety, reducing costs, improving quality and increasing flexibility. Well done, automation can lead to improvements in all of these areas, but the balance of benefits can vary by technology and approach. The right balance for any business depends on its overall operational strategy and business goals:

  • Automation programs must start with a clear definition of the problem. It is also important that this includes the reasons why automation is the right solution. Each project should be able to identify where and how automation can offer improvements and how those improvements are related to the overall strategy of the company.

  • Automation must have a clear return on investment. Organizations, especially large ones, should be careful not to over-specify, over-complicate, or over-spend their automation investments. Choosing the right level of complexity to meet current and foreseeable future requirements requires a deep understanding of the company's processes and manufacturing systems.


Here are some features from the Lean.IQ IoT solution kit:

MATERIAL & ASSET TRACKER Collecting real-time data on all critical assets’ location & condition in real-time throughout the entire manufacturing process.

SHELF-LIFE MANAGER Automatically calculates materials exposure time left in real-time and assigns best material for job. Tracks remaining shelf-life and validates that jobs will complete on time, while maximizing material usage.

QUALITY MANAGER Collects sensor data enabling improved quality control. Advanced AI-based tools offer predictions and identify root-cause for quality issues, creating full digital traceability and ensuring full compliance with regulations and audit processes.

TOOL MANAGER Tracks tools’ location and status while optimizes maintenance and service. Locates missing and misplaced tools to reduce disruption due to tools’ availability.

WIP OPTIMIZER Locates and tracks all types of WIP (Work In Process). Shows work order progress and warns if it is in risk of being late. Reduces errors, promoting accuracy and allowing greater visibility throughout the entire order fulfillment including AI-based bottlenecks prediction.

MANUFACTURING OPTIMIZATION Leverages Industrial IoT & AI-based technologies to digitize factories, track & trace all tools, parts and materials, creating the digital twin and allowing full traceability of the Digital Thread from raw material to end-product.


Nothing is more important to us than the exchange to establish common goals for the project. Leading workflow performance through maximizing full transparency of the individual processes, identifying bottlenecks and providing access to data for better decision making.

  • Increased production throughput & yield

  • Reduced production costs, re-work & waste

  • Digitalization replaces paperwork, spreadsheets & manual tasks

  • Enhanced visibility through real-time tracking factory floor assets.

  • Improved quality & quality control by full traceability of the digital thread from raw material to end product

  • Improved auditability and audit readiness

  • Defect repetition prevention by automatic tool utilization and work cycles tracking

  • Increased staff efficiency through paperless and streamlined production environment

  • Cloud-based solution with minimal upfront expenditure. Faster ROI.

  • Enterprise-class security. ISO 27001 certified.

You may ask what our solution differentiates from others? Well, here we go, just to mention some of the unique benefits:

  • Easy to use - For administrators setting up the system, ExoSense’s code-less environment for configuring digital assets, rules, permissions, and visualizations can be learned in an afternoon.

  • Low-barrier proof of concepts - our pricing model, fast deployment, and onboarding packages get customers to a POC in days.

  • Functionality - We are responsive to the functionality we asked for. I focus is on what is needed to be accomplished and then build it in a way that can be leveraged by our products and different types of market applications. Together with our partners we continuously release updates, and deliver as a partner on eye level which you can trust.

  • Hardware partnerships - We offer IoT Connector integrations for a multitude of gateways, connectivity platforms, and off-the-shelf hardware. We work with market leading sensor and wireless companies so that we have options to develop overall solutions.

  • It just works - It's important — digitization in industrial use cases will not happen if it's not adopted by engineers and maintenance teams with a low tolerance for flaky software. It's reliable and no platform shows data updates as close to real-time as ours. The software just works and is easy to use.

Contact us for more information and a complimentary briefing and assement!


5 Ansichten0 Kommentare


bottom of page