Data Science × Manufacturing

AI in manufacturing: Your machines know more
than your reporting shows

6 modules. 6 problems every manufacturer knows. 6 data-driven solutions that turn the data you already have into measurable savings, drawing on MES, ERP/SAP, sensor & SCADA data, production planning and inspection data. No external data, no new hardware.

Calculated savings potential per year
€0
Model calculation for a sample plant with 48 machines · derived from documented assumptions
At a glance

Numbers you can trace back

Based on a mid-sized manufacturer: €85M revenue, 320 employees, 48 machines in 3-shift operation. Every figure is derived from the documented assumptions.

6
Modules
48
Machines in the sample plant
€2,045,800
Savings potential/year
4 wks
Pilot timeframe
The 6 modules

Each module solves a concrete manufacturing problem

Click a module for the full analysis with visualisations, transparent model calculation and business impact.

Module 01
Predictive Maintenance
Survival models and LSTM detect machine failure before it happens, based on sensor and maintenance history. Reduces unplanned downtime cost.
€216,000
Savings / year
SurvivalLSTM
Module 02
Scrap & Quality Forecast
Gradient boosting detects from batch, parameters and inspection data which production leads to scrap. Lowers material and rework cost.
€419,000
Savings / year
Gradient BoostingXGBoost
Module 03
OEE & Bottleneck Optimisation
Process mining exposes setup times, cycle losses and bottlenecks. Capacity gained without investment, from MES and PPS data.
€604,800
Capacity value / year
Process MiningOptimierung
Module 04
Energy & Load Optimisation
Time-series models forecast consumption per machine and shift and smooth load peaks. Cuts energy cost and peak-demand charges.
€264,000
Savings / year
ZeitreihenRegression
Module 05
Demand & Production Planning
Forecasting reduces over- and underproduction and tied-up stock. Less working capital, fewer rush orders, from ERP and PPS history.
€294,000
Savings / year
ForecastingGradient Boosting
Module 06
On-Time Delivery Forecast
Classification and survival models flag early which orders will be late. Avoids contract penalties and protects customer relationships.
€248,000
Savings / year
KlassifikationSurvival
Savings potential by module: overview
Interactive

The Manufacturing Simulator

S01-S04
Four simulations, all assumptions disclosed
Bottleneck hours via overall equipment effectiveness, downtime costs as a distribution, the economic maintenance interval and scrap costs: set the sliders to the scale of your plant. Every calculation path sits beneath its simulation.
Open all four simulations →
Our approach

No theory - results in weeks

We work with the data you already have. No vendor lock-in, no cloud mandate, no hidden costs.

🏭
Industry knowledge + data science
We understand maintenance, scrap and shift operation. Our models solve real manufacturing problems, GDPR-compliant and on your infrastructure.
⚡
Results before perfection
We deliver a pilot dashboard with real numbers from your data. No 6-month concept - you see the ROI before you invest.
🔒
Your data, your systems
We connect what already exists in your plant: MES, ERP/SAP, sensor & SCADA data, PPS, quality and inspection data. No new system, no external data.
Note on the context of this portfolio

The following six modules use a fictitious mid-sized manufacturer (48 machines, 3-shift operation, €85M revenue) to show how data science can be applied across production, from predictive maintenance to on-time delivery.

All euro figures are model calculations. They are derived transparently from clearly named assumptions (assumption baseline → lever → result) and serve only to illustrate the order of magnitude of the achievable impact, not promises.

In a real project, the domain expertise of your plant is the decisive factor: How are your machines connected? What data sits in MES, ERP and the control system? Where do the biggest losses occur, in downtime, scrap or energy? On that basis we build models that fit your reality.

This portfolio shows which questions data science can answer in manufacturing. The concrete answers emerge only with your data.

Ready to put your data to work?

We work with the data you already have. No vendor lock-in, no cloud mandate, no hidden costs.

Schedule a data workshop →