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IOT and AI Services for Manufacturing

Downtime

Down 22% after 90-day pilot

  • Why it matters

Modern Manufacturing Runs on Connected Data

Manufacturers under pressure from cost, quality and delivery targets need more than dashboards. IOT and AI turn machine, sensor and process data into decisions that improve output, protect assets and lift margin.

Intelisense IT helps organisations use technology more effectively. We move teams away from outdated ways of working and towards connected digital platforms that improve access to information, strengthen decision-making and create better experiences for service users and stakeholders.

  • Real-time visibility across your production environment
  • Predictive maintenance that reduces unplanned downtime
  • Data connected to Dynamics 365, Power BI and Microsoft Fabric
  • A practical proof of concept before wider rollout
  • Problems we solve

The problems holding your data and your business back

Most manufacturers do not have a data problem. They have a fragmentation, quality and readiness problem. Click any segment of the wheel to explore the recurring themes we hear on the shop floor and in the boardroom.
Data Challenges Wheel - Pie Divs
LIMITED
VISIBILITY
ASSET
INTEGRITY
RISK
HEAVY MANUAL
REPORTING
MISSED
MARGIN
AGEING
SYSTEMS
UNPLANNED
DOWNTIME
Limited Visibility
Asset Integrity Risk
Heavy Manual Reporting
Missed Margin
Ageing Systems
Unplanned Downtime
DATA CHALLENGES

Limited visibility

Production data is trapped in machines, spreadsheets and disconnected systems.

Asset integrity risk

Critical equipment fails without early warning, affecting quality and safety.

Manual reporting

Teams spend hours pulling numbers instead of acting on what the numbers say.

Missed margin

Without connected data, productivity, yield and resource utilisation plateau.

Ageing systems

Legacy control and ERP systems can’t keep pace with modern operating models.

Unplanned downtime

Reactive maintenance disrupts schedules and pushes costs beyond forecast.
  • Benefits

From Reactive Operations to a Data-Led Operating Model

A connected manufacturing environment gives leaders across operations, engineering, IT and finance a single, trustworthy view of performance.
Less downtime

Detect vibration, temperature and pressure anomalies before they become failures.

Better decisions

AI models surface the signal in production data so teams act on what matters.

Smarter assets

Move from reactive fixes to condition-based and predictive maintenance.

Higher yield

Reduce scrap and rework by monitoring process parameters in real time.

Remote monitoring

See equipment, lines and sites from one Microsoft-based operations view.

Scalable model

Start on a single asset or line, then extend across the plant and estate.

  • How we help

A Practical Toolkit for Connected Manufacturing

Every engagement blends discovery, engineering and change grounded in the Microsoft platform your teams already know.

Microsoft Digital Twins

Build a digital map of your factory, production lines, assets and processes so teams can simulate, monitor and improve operations in one place.

IOT Sensor and Device Programmes

Deploy sensors for temperature, vibration, pressure, usage and machine performance with secure ingestion into Azure.

Data Platform on Azure and Fabric

Land production data alongside ERP, quality and supply chain data with governed pipelines built for scale.

AI for Production Insight

Detect anomalies, forecast failures and highlight process drift so leaders act before problems escalate.

Power BI Operational Views

Give plant, line and asset owners the metrics they actually use OEE, downtime, yield, energy and cost per unit.

  • Our process

From First Conversation to Production Insight

A pragmatic path that respects your operations calendar and starts small.
01
Discovery Workshop

We map the operations, question the data you already have and where visibility is missing today.

02
Proof of Poncept

A focused build usually one asset, line or use case to prove value inside a defined timebox.

03
Scale-out Roadmap

Extend across lines, plants and the wider estate with a governed platform and clear ROI model.

04
Operate and Improve

Ongoing tuning of models, dashboards and integrations as your operating model matures.

  • Digital twins

A Live Digital Map of your Factory

Microsoft Digital Twins let you model plants, lines, assets and processes then feed them with live IOT signals and ERP context so decisions match reality.
Temperature and pressure
Vibration and motion
PLC and machine data
Throughput and OEE
  • Operational outcomes

A structured 5-stage journey

  • Stage 1 of 5

Connect

What we do
Deploy IOT sensors and secure data ingestion across the assets and lines that matter most without disrupting existing control systems.
  • Sensor and gateway rollout
  • Secure ingestion into Azure
  • OT/IT boundary respected
Outcome
A single, trustworthy live feed from your production environment the foundation everything else runs on.
  • Stage 2 of 5

Monitor

What we do
Stand up real-time operational views for plant, line and asset owners OEE, downtime, yield and throughput in one place.
  • Live OEE and downtime dashboards
  • Role-based Power BI views
  • Alerts to the right people
Outcome
Teams see what’s happening on the floor as it happens, not the next morning in a spreadsheet.
  • Stage 3 of 5

Predict

What we do
Apply AI models to vibration, temperature, pressure and cycle data to spot anomalies and forecast failures before they escalate.
  • Anomaly detection
  • Predictive maintenance signals
  • Model tuning to your assets
Outcome
Move from run-to-failure to condition-based maintenance on the equipment that hurts most when it stops.
  • Stage 4 of 5

Optimise

What we do
Feed production data back into Dynamics 365, Fabric and business processes to lift yield, reduce scrap and improve resource use.
  • Yield and scrap reduction
  • Energy per unit tracking
  • Closed-loop with D365
Outcome
Measurable gains in productivity, quality and cost per unit with numbers finance and operations both trust.
  • Stage 5 of 5

Scale

What we do
Extend the proven pattern across lines, plants and the wider estate on a governed Microsoft platform built to grow.
  • Multi-site rollout
  • Governed data platform
  • Roadmap tied to ROI
Outcome
A repeatable, data-led operating model not a one-off pilot that stalls after go-live.
  • Getting started

Start Small. Prove Value. Then Scale

Most manufacturers get furthest by starting with a focused proof of concept on one asset, line or use case. Where available, we can also help explore specialist funding routes for innovation and digital manufacturing projects, support is limited and outcomes aren’t guaranteed, but we’ll tell you honestly if it applies.

Fixed-scope proof of concept

Defined success measures agreed upfront

Clear route from pilot to production

Guidance on possible funding avenues, where relevant

  • FAQs

Questions we Hear from Manufacturing Leaders

Not seeing your question? Book a short call and we’ll cover it directly.
Talk to an expert
Do we need to replace our existing machines or control systems?
No. Most engagements add sensors and secure data ingestion alongside existing PLC, SCADA and ERP systems we don’t rip and replace what already works.
Production data lands in Azure and Microsoft Fabric so it can be joined with Dynamics 365 and surfaced in Power BI giving operations, finance and IT the same numbers.
A focused proof of concept on one line, asset or use case typically scoped over a few weeks is the fastest way to prove value before wider investment.
We build on Microsoft’s enterprise security model with least-privilege access, identity via Entra ID, and clear data ownership boundaries between OT and IT.
Where relevant, we can point you towards specialist innovation and digital manufacturing funding routes. Availability is limited and eligibility varies we’re upfront about what applies.

Ready to Grow Your Business?

Transform your digital presence with tailored solutions that drive results. Let’s take your brand to the next level today

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