Manufacturing & Industrial Intelligence
Smart Factory.
Real Throughput.
We deliver end-to-end manufacturing intelligence — from plant floor to ERP — so production runs on precision, not guesswork.
Production Throughput Optimisation
Real-time OEE tracking, bottleneck detection, and capacity uplift across multi-shift production.
Quality & Compliance Control
Inline quality checkpoint systems, SPC integration, and zero-escape defect frameworks.
ERP & MES System Integration
SAP, Oracle, and Infor ERP transformation with MES connectivity and real-time data fabric.
ERP ► Production
● PRODUCTION LIVE
Quality ► Scan
99.2%
Yield Rate
+2.1% vs target
Automation
847
Cycles / Hour
4 Lines Active — All Nominal
Materials ► Stock
97.4%
Material Readiness
● On-Hand Nominal
Operating Pressures
The Manufacturing Intelligence Gap
Modern manufacturers face compounding operational pressure across production, quality, supply chain, and legacy infrastructure. We map it, and then we resolve it — end to end.
Production Throughput Gaps
Unplanned downtime, micro-stoppages, and changeover delays erode capacity before they're even measured. Manual OEE tracking hides the true loss.
OEE · Throughput · Capacity
Quality Escape & Rework Costs
Late-stage defect detection drives high scrap rates and rework loops. Disconnected inspection systems fail to trigger upstream prevention.
Quality · SPC · Scrap Rate
Supply Chain Volatility
Supplier disruptions, extended lead times, and demand variability outpace manual planning. Material shortages halt lines before procurement responds.
Supply Chain · MRP · Demand
Legacy System Fragmentation
Disconnected MES, ERP, and SCADA systems create data silos that prevent real-time decision-making and drive costly manual reconciliation.
ERP · MES · Integration
Operating Environments
Manufacturing Operating Environment
Select your operational domain. Our capabilities span the full manufacturing stack — from plant floor execution to digital twin and ERP layer.
Plant Floor Execution
Work order management, operator guidance systems, shift handover tools, and real-time production tracking across multi-cell environments.
Quality Systems Integration
Inline inspection, SPC monitoring, PPAP, and APQP process integration. Connects CMM data, vision systems, and gauging directly to the production record.
Maintenance & Uptime Management
Predictive maintenance scheduling, work order automation, spare parts optimisation, and CMMS integration to eliminate unplanned downtime.
Production Planning & Scheduling
Finite capacity scheduling, demand-driven MRP, and real-time shop-floor schedule adherence with dynamic re-sequencing capability.
▸ Production Flow Pathway
Demand Planning & Forecasting
Statistical demand sensing, seasonality modeling, and multi-echelon inventory optimisation to reduce both stockouts and excess inventory.
Supplier Network Management
Supplier qualification, performance scorecards, risk tiering, and dual-sourcing strategy to build resilient, audit-ready supply networks.
Inbound Logistics & WMS
Warehouse management, receiving, putaway, and slotting strategy aligned with production pull signals and JIT delivery requirements.
Inventory Optimisation
Safety stock modeling, reorder point calculation, and multi-site inventory balancing to reduce working capital while maintaining fill rates.
▸ Supply Chain Pathway
SAP & Oracle ERP Transformation
Full SAP S/4HANA and Oracle Cloud Manufacturing implementation, migration, and optimisation with manufacturing-specific process design and integration.
MES & SCADA Integration
Bidirectional data integration between MES, SCADA, PLCs, and ERP layers using ISA-95 standard. Real-time production data fabric across the plant.
Digital Twin & IIoT Architecture
Asset digital twins, real-time sensor integration, edge computing architecture, and IIoT platform design for predictive and prescriptive intelligence.
Analytics & Reporting Layer
Manufacturing BI dashboards, production KPI towers, and executive operations reporting with drill-through to shift, line, and SKU level detail.
▸ Automation Layers
Delivery Capabilities
Manufacturing Execution Model
Five integrated capability domains working as a connected system — from strategic planning through continuous production improvement. Not a service list. A manufacturing operating model.
Capability 01
Production Planning & MPS Design
Master production scheduling, rough-cut capacity planning, and demand-to-production translation across single and multi-site environments. Connects S&OP output to executable shop-floor plans.
Capability 02
Quality Systems & Inspection Integration
End-to-end quality management from APQP through production, connecting SPC, gauge calibration, CMM, and audit-ready traceability with zero-escape targets.
Capability 03
Maintenance & Asset Reliability
Predictive maintenance programs, CMMS optimisation, TPM rollouts, and spare parts rationalisation. Targets MTBF improvement and unplanned downtime elimination at cell, line, and plant level.
Capability 04
Materials Management & Inventory Control
Material requirements planning (MRP), warehouse optimisation, kanban design, and supplier-side pull systems to eliminate material-driven line stoppages and reduce working capital.
Capability 05 — Integration Backbone
ERP, MES & Digital Operations Integration
The connective layer across all four capabilities. SAP, Oracle, Infor, and custom ERP integration with MES, CMMS, WMS, and plant-floor systems. Unified data fabric enabling real-time decision intelligence across production, quality, maintenance, and supply chain — simultaneously.
Transformation Pathway
Six-Stage Production Improvement
A structured, sequenced programme that takes manufacturing operations from baseline assessment to continuous improvement at pace — without disrupting live production.
01
Stage 01
Production Baseline & Assessment
OEE baseline, production loss waterfall analysis, and operating model diagnostic. Identifies the highest-value improvement opportunities before any change is made.
02
Stage 02
Quality & Defect Elimination
Root cause analysis, PFMEA update, and inline detection system design. Targets zero-escape quality with SPC-driven control plans and audit readiness.
03
Stage 03
Maintenance Reliability Programme
TPM deployment, preventive maintenance schedule design, and predictive maintenance sensor integration. CMMS configuration and maintenance KPI dashboards.
04
Stage 04
Materials & Supply Chain Realignment
MRP configuration, safety stock optimisation, supplier lead time reduction, and kanban system implementation. Eliminates material-driven production interruptions.
05
Stage 05
ERP & MES System Optimisation
Transaction cleanup, master data governance, MES configuration, and production reporting rationalisation. Turns system data into real-time manufacturing intelligence.
06
Stage 06
Continuous Improvement & CI Culture
Structured CI governance, Lean/Six Sigma competency build, KPI tower design, and management operating system rollout. Embeds a self-sustaining improvement engine in the organisation.
Why DT Solutions
Built for Manufacturing.
Delivered at Pace.
We don't arrive with frameworks. We arrive with manufacturing domain knowledge, pre-built accelerators, and a delivery model designed around live production constraints — so change happens without stopping the line.
▸ Production Continuity Assurance
PLAN
DESIGN
BUILD
DEPLOY
RUN
98%
On-time delivery rate across active programmes
140+
Manufacturing engagements delivered
Zero
Production stoppages caused by our deployments
Manufacturing Domain Specialists Only
Every engagement is led by consultants with direct manufacturing operations experience — not generalist project managers relearning the domain.
Rapid Time-to-Value Delivery Model
Pre-built manufacturing accelerators, templates, and ERP configuration packages compress implementation timelines by 30–40% versus traditional delivery.
Zero Production Disruption Guarantee
Our deployment protocols are designed around live-line constraints. Change is sequenced, tested in shadow, and cutover in planned windows — never during production runs.
End-to-End ERP & MES Integration Capability
SAP, Oracle, Infor, Microsoft Dynamics — plus MES, CMMS, WMS, and SCADA. Full stack integration capability in a single partner relationship.
Measurable Output Accountability
We agree OEE improvement targets, quality yield metrics, and uptime KPIs upfront. Delivery is measured against those numbers — not project milestones.
Start Your Manufacturing Transformation
Ready to Run Smarter
Production Operations?
Talk to a DT Solutions manufacturing specialist. We'll map your operating gaps, identify your highest-value opportunities, and outline a delivery approach built around your production schedule.
Production Optimisation
Quality Systems
ERP & MES Integration
Maintenance & Reliability
Supply Chain Realignment