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MANUFACTURING ENGINEERING

Your MES Talks to the Line. Your ERP Talks to Finance. We Make Them Talk to Each Other.

APPWRK is a consulting and engineering partner for manufacturers who need their IT/OT stack to actually work together. We assess your factory floor systems, architect the integration layer, and build the AI models that turn sensor noise into autonomous decisions. From MES to ERP to edge, across discrete and process manufacturing.

Trusted by global enterprises
UNILEVER
IFB INDUSTRIES
GLOBAL FREIGHT OPS
Only 21%
of manufacturers are fully AI-ready, per TCS-AWS 2025 study. The gap is real.
4x Growth
Deloitte predicts agentic AI adoption in manufacturing will jump from 6% to 24% by 2026.
54%
of industrial firms cite data quality as the top barrier to scaling AI, per IIoT World 2025 survey.
10+
Years in Enterprise Engineering
150+
Engineers Across Stack
50+
Enterprise Engagements
Global
Multi-Site Deployments

Your Factory Floor Has Data. Your Boardroom Needs Decisions. The Middle is Broken.

We have heard these from manufacturing CTOs and IT directors at every stage of digital maturity.
🔗

The MES-ERP Gap is Costing You Millions

Your MES captures cycle times, reject rates, and machine states in real time. Your ERP runs financial planning on yesterday's batch reports. Between them sits a CSV export, a night shift supervisor, and a prayer. That gap between operational data and business logic is where your margin leaks.

🏭

OT and IT Still Live in Separate Centuries

Your PLCs run Modbus. Your cloud team speaks REST APIs. The OT team trusts no one with network access, and the IT team does not understand ladder logic. Until someone bridges this IT/OT convergence gap with proper ISA-95 architecture, your "smart factory" initiative stays on slide 12 of a PowerPoint deck.

🤖

AI POCs That Never Leave the Lab

You ran a predictive maintenance pilot on one CNC machine. The data science team showed a great confusion matrix. Six months later, it is still a Jupyter notebook on a laptop. Nobody wired it into your CMMS. Nobody built the edge inference layer. IDC confirms: only 5% of GenAI projects reach production scale across industries.

👴

The Knowledge is Retiring Before the Machines

Your most experienced process engineer is 58. He knows why Line 3 vibrates on Tuesdays and which supplier's raw material causes that specific defect. None of this is documented in any system. When he retires, decades of tribal knowledge walk out the door. The "silver tsunami" is not coming; it is already here.

📊

Dashboards Everywhere, Decisions Nowhere

You have invested in BI tools, SCADA historians, and a data lake that is rapidly becoming a data swamp. Operators see 14 dashboards per shift but still make decisions based on gut feel. The problem is not visualization. The problem is that nobody built the decision intelligence layer between raw telemetry and actionable prescriptions.

Consulting + Engineering + AI: Under One Roof

Most firms either advise or build. We do both, with AI embedded from day one, not bolted on as an afterthought.
🧭

Manufacturing IT Consulting

We assess your current IT/OT architecture, map your ISA-95 levels, identify integration bottlenecks, and deliver a prioritized roadmap your CFO can actually fund.

  • IT/OT convergence assessment and ISA-95 mapping
  • MES/ERP integration architecture review
  • AI readiness audit across plant sites
  • Technology vendor evaluation and selection
⚙️

Platform Engineering

We build the middleware, integration layers, and custom platforms that connect your shop floor to your enterprise systems. Not another dashboard. Real data plumbing.

  • Custom MES and production tracking platforms
  • ERP integration middleware (SAP, Oracle, Infor)
  • Edge computing and IIoT gateway engineering
  • Cloud-native manufacturing data platforms
🧠

AI and Automation

We take your AI from Jupyter notebook to production. Predictive maintenance models deployed on edge. Computer vision on the line. Agentic workflows that close the loop without a human in every step.

  • Predictive and prescriptive maintenance at edge
  • Computer vision quality inspection systems
  • Agentic AI for autonomous scheduling
  • Digital twin simulation and optimization

Deep Expertise Across Manufacturing Segments

🔧

Discrete Manufacturing

Automotive, consumer durables, electronics, and industrial equipment. Where BOM management, assembly line optimization, and supplier quality matter. We have built systems for global OEMs handling 80,000+ monthly customer interactions.

AUTOMOTIVE CONSUMER DURABLES ELECTRONICS INDUSTRIAL EQUIPMENT
🧪

Process Manufacturing

Chemicals, food and beverage, pharmaceuticals, and materials. Where batch management, recipe control, and regulatory compliance define your operations. Continuous process optimization and yield improvement through AI-driven parameter tuning.

CHEMICALS F&B PHARMA MATERIALS
📦

Contract and OEM Manufacturing

Multi-client production scheduling, rapid changeover management, and customer portal engineering for Tier-1, Tier-2, and Tier-3 suppliers. We understand the unique challenges of running multiple product lines for different OEMs on the same floor.

TIER-1 SUPPLIERS CONTRACT MFG OEM PARTNERS

Across Your Entire Manufacturing Value Chain

From product design intelligence to aftermarket service, we engineer the connective tissue between every stage.
Product Design
PLM integration, generative design tools, digital thread
CONSULTING
Supply Chain
Supplier portals, demand sensing, procurement automation
ENGINEERING + AI
Production
MES, scheduling, OEE optimization, edge AI inference
ENGINEERING + AI
Quality
SPC, vision inspection, defect prediction, CAPA automation
AI
Logistics
WMS, yard management, freight optimization, track-and-trace
ENGINEERING
Service
Field service AI, warranty analytics, customer service bots
AI

Four Engineering Pillars for the Intelligent Factory

P1 8-16 weeks

Smart Factory Platform Engineering

The integration backbone that connects your shop floor systems to enterprise applications. We build the middleware that your MES vendor never finished and your ERP integrator said was "out of scope."

  • MES-ERP bi-directional integration (SAP, Oracle, Infor, custom)
  • IIoT gateway and edge computing infrastructure
  • Unified manufacturing data platform on cloud or hybrid
  • ISA-95 compliant integration architecture
AI LAYER Anomaly detection on equipment telemetry, automated data quality scoring
Discuss Platform Needs →
P2 10-20 weeks

Production Intelligence and AI

From predictive maintenance to autonomous scheduling. We deploy AI models where they matter: on the edge at the machine, not in a data science sandbox. IDC predicts 40% of manufacturers will have AI-driven autonomous scheduling by end of 2026.

  • Predictive and prescriptive maintenance deployed at edge
  • Computer vision quality inspection (surface, dimensional, assembly)
  • AI-driven production scheduling and sequencing
  • Digital twin simulation for process optimization
AI LAYER Agentic AI workflows: detect anomaly, check CMMS, schedule tech, generate work order. Autonomously.
Discuss AI Deployment →
P3 8-14 weeks

Supply Chain and Logistics Engineering

We have built Unilever's global Yard Management System (Intelligate) and multi-modal freight platforms. We apply the same rigor to your inbound logistics, warehouse operations, and outbound distribution.

  • Warehouse Management System (WMS) customization and build
  • Yard Management and dock scheduling platforms
  • Multi-modal freight management and TMS integration
  • Supplier portal and procurement workflow automation
AI LAYER Demand sensing, supplier risk scoring, route optimization with real-time constraints
Discuss Supply Chain Needs →
P4 6-12 weeks

Workforce and Customer Experience

Your operators need better interfaces than green-screen terminals from 1998. Your customers want self-service portals with real-time order visibility. We have built conversational AI handling 80,000+ monthly customer calls for IFB Industries.

  • Operator-facing mobile and tablet applications
  • Conversational AI for customer service and field support
  • Employee training and knowledge management platforms
  • B2B customer portals with order tracking and self-service
AI LAYER GenAI knowledge assistants that capture tribal knowledge; NLP-driven customer intent routing
Discuss Experience Needs →

From Jupyter Notebook to Production Line. That is the Hard Part.

Everyone can build a demo. We build AI systems that survive third shift, network outages, and operators who do not trust black boxes.

2026 is the year manufacturing AI moves from "pilot purgatory" to production. Agentic AI systems are no longer theoretical; they autonomously detect anomalies, query ERP for parts, schedule technicians, and generate work orders in a single integrated sequence. We build these systems with the governance, explainability, and edge deployment rigor that manufacturing environments demand.

🔮

Prescriptive Maintenance

Beyond predicting failures. Our models tell the operator exactly what to do: the specific part, the timeframe, and the action required. Deployed on edge for sub-second inference, even when the network goes down.

👁️

Computer Vision QC

Surface defect detection, dimensional verification, and assembly validation at line speed. We train models on your specific product geometry, not generic datasets. Typical ROI within 3 to 6 months.

🤖

Agentic Factory Workflows

Multi-agent systems that orchestrate production decisions autonomously. Using A2A and MCP protocols, our agents connect to your SAP, CMMS, and SCADA in real time. Shifting from "human-in-the-loop" to "human-on-the-loop."

🌐

Digital Twin Engineering

High-fidelity simulation environments where you test process changes, new configurations, and AI models before touching the physical line. PepsiCo identified 90% of potential issues before physical modifications using this approach.

AI Proof Points

80,000+
Monthly AI-handled customer calls
IFB Industries conversational AI platform
95%
Query time reduction with NL-to-SAP
Industry benchmark: agentic SAP querying
40%+
Of manufacturers upgrading to AI scheduling by 2026
IDC Manufacturing FutureScape prediction
3-6 mo
Typical ROI timeline for CV quality inspection
Per IIoT World Days 2025 deployment data

Real Engagements. Real Manufacturing Impact.

UNILEVER

Global Yard Management System: Intelligate

Built Unilever's enterprise-wide Yard Management Solution from the ground up. Real-time dock scheduling, vehicle tracking, and throughput optimization across global manufacturing and distribution sites. Integrated with SAP logistics and warehouse management modules.

Global
Multi-site deployment
Real-Time
Dock and yard visibility
SAP
Enterprise integration
24/7
Operational uptime
Yard Management SAP Integration IoT Real-Time Tracking
View Case Study →
IFB INDUSTRIES

AI-Powered Customer Service Platform

Designed and deployed a conversational AI platform for IFB, one of India's largest consumer durables manufacturers. The system handles product queries, service booking, complaint resolution, and warranty management, reducing call center load while improving first-contact resolution rates.

80,000+
Monthly AI-handled calls
NLP
Intent classification engine
Multi
Channel deployment
24/7
Autonomous operation
Conversational AI NLP Customer Service Manufacturing
View Case Study →
GLOBAL LOGISTICS

Multi-Modal Freight Management System

Built a comprehensive freight management platform handling multi-modal transportation (road, rail, sea, air). End-to-end shipment tracking, carrier management, rate optimization, and customs documentation. Directly relevant to manufacturing outbound logistics and distribution.

Multi-Modal
Transportation modes
End-to-End
Shipment visibility
Automated
Rate optimization
Real-Time
Carrier management
Freight Management TMS Logistics Supply Chain
View Case Study →

We Integrate With Your Existing Stack. We Do Not Rip and Replace.

Your SAP stays. Your Siemens PLCs stay. We build the intelligence layer on top and between.
SAP S/4HANAERP
Oracle CloudERP
Infor CloudSuiteERP
Microsoft DynamicsERP
Siemens OpcenterMES
Rockwell PlexMES
AVEVA MESMES
Custom MESMES
AWS IoTCLOUD / IIoT
Azure IoT HubCLOUD / IIoT
Google Cloud AICLOUD / AI
NVIDIA OmniverseDIGITAL TWIN
Apache KafkaDATA PIPELINE
Python / TensorFlowAI / ML
Node.js / ReactAPPLICATION
OPC-UA / MQTTPROTOCOL

Not a Body Shop. Not a Slide Deck Firm. Not an AI Demo Factory.

VS. GENERIC DEV SHOPS

We Speak ISA-95, Not Just REST APIs

Generic offshore development shops can build you a web app. They cannot tell you why your OPC-UA server is dropping tags or how to structure a unified namespace for 200 PLCs. We understand manufacturing IT/OT architecture because we have built systems for Unilever's factory floors, not just their marketing websites.

VS. STRATEGY-ONLY CONSULTING FIRMS

We Build What We Recommend

McKinsey and Deloitte will hand you a 200-page digital transformation playbook. Then you spend six months finding someone to actually build it. We consult, architect, and engineer the solution. One team, one accountability chain, no "strategy-to-implementation" handoff gap.

VS. AI HYPE VENDORS

Production AI, Not Demo AI

AI startups show impressive demos on clean datasets. We build AI systems that survive noisy sensor data, network outages at 2 AM, and operators who will bypass anything they do not trust. Our IFB deployment handles 80,000+ real calls monthly, not 80,000 test cases in a controlled environment.

VS. BODY SHOPS / STAFF AUGMENTATION

Outcome-Driven Squads, Not Seat-Warmers

We do not rent you developers by the hour and wait for your team to manage them. We deploy cross-functional squads with manufacturing domain knowledge, engineering leads, and AI specialists who own the delivery outcome. You get a working system, not a bench of contractors waiting for tickets.

Engineers Who Have Shipped Manufacturing Systems, Not Just Read About Them

Manufacturing Solutions Architect

ISA-95 mapping, IT/OT convergence design, integration architecture. Bridges the gap between your plant engineers and your cloud team.

IIoT and Edge Engineers

OPC-UA, MQTT, edge gateway deployment, PLC data extraction, real-time telemetry pipelines from shop floor to cloud.

AI/ML Engineers

Predictive models, computer vision, NLP, and agentic workflows. Specialized in deploying models on industrial edge hardware, not just cloud GPUs.

Full-Stack Platform Engineers

Custom MES modules, ERP middleware, data platforms, operator interfaces. Production-grade code with CI/CD and automated testing.

AI Delivery Engine for Manufacturing

Every manufacturing engagement includes our AI delivery layer, ensuring intelligence is built in, not bolted on after the platform ships.

Edge Inference

Models optimized for industrial edge: NVIDIA Jetson, Intel Movidius, or standard industrial PCs.

MLOps Pipeline

Model versioning, A/B testing, drift detection, and automated retraining on new production data.

Explainability Layer

Operators see why the AI made a recommendation. No black boxes on the factory floor.

Governance and Audit

Full decision logging, compliance trails, and human override protocols for regulated environments.

150+
Engineers Across Stack
10+
Years Enterprise Delivery
24/7
Production Support Coverage

Start Where You Are. Scale When You Are Ready.

Whether you need a 4-week assessment or a 12-month transformation, we have a model that fits.
TIER 1

Factory AI Readiness Assessment

4-6 weeks

We audit your IT/OT stack, assess AI readiness across plant sites, and deliver a prioritized roadmap with quick wins and long-term bets. You get clarity on where to invest first.

  • IT/OT architecture and ISA-95 level mapping
  • Data quality and integration gap analysis
  • AI use case prioritization (ROI-ranked)
  • 90-day implementation roadmap
  • Executive presentation with business case
Start Assessment →
TIER 3

Enterprise Manufacturing Transformation

6-18 months

Multi-site rollout. Multi-pillar delivery. We become your manufacturing technology partner, embedding squads across your organization to drive continuous improvement with AI at the core.

  • Multi-site platform deployment and standardization
  • Enterprise AI Center of Excellence setup
  • Continuous model improvement and retraining
  • Quarterly business reviews and ROI tracking
  • Technology roadmap co-evolution
Discuss Transformation →

Questions Manufacturing IT Leaders Ask Us

No. We are not a platform vendor competing with SAP, Siemens, or Rockwell. We are the engineering team that builds around, on top of, and between those platforms. Your SAP S/4HANA stays. Your Siemens Opcenter stays. We build the integration middleware, the AI layers, and the custom applications that make your existing investments work together. Think of us as the connective tissue between your enterprise systems.

Large IT services firms are excellent at staffing large teams and running multi-year programs. But if you need a focused, outcome-driven squad that can go from architecture to production AI in 10 to 20 weeks, you will find their model too slow and their bench too generalist. We are a consulting plus engineering partner. We advise, architect, and build with the same team. No "strategy-to-implementation" handoff. No rotating benches. Your project lead on day one is your project lead on go-live day.

This is our core strength. Most AI pilots fail not because the model is bad, but because nobody built the engineering infrastructure around it: the edge inference layer, the data pipeline, the integration with CMMS or MES, the operator interface, the MLOps pipeline for retraining. We take your existing models (or build new ones) and wrap them in production-grade infrastructure. Our IFB deployment handles 80,000+ real calls every month. That is production, not a pilot.

That is exactly what Tier 1 is designed for. Our 4 to 6 week Factory AI Readiness Assessment maps your current IT/OT architecture, evaluates data quality across plant sites, and delivers a prioritized set of AI use cases ranked by ROI and implementation complexity. You get a clear roadmap, not a vague strategy deck. Many of our Tier 2 engagements start this way, because the assessment reveals quick wins that fund the larger transformation.

Yes. Discrete manufacturing (automotive, electronics, consumer durables) and process manufacturing (chemicals, F&B, pharma) have different data signatures, different quality requirements, and different regulatory constraints. Our IFB work sits firmly in the discrete world (consumer durables). Our supply chain and logistics platforms serve both. We staff teams with engineers who understand the specific domain, not generalists who need three months to learn your terminology.

We respect the OT/IT boundary. Our architecture designs use DMZ-based data diode patterns, edge processing (so raw telemetry never leaves the plant network), and comply with IEC 62443 industrial cybersecurity standards. For highly regulated environments, we deploy models on local edge hardware with no cloud dependency. We work with your OT security team, not around them. Our Unilever deployment operates within their global IT security framework.

Your Factory Data is Waiting to Become Your Competitive Advantage

Whether you are planning your first AI pilot or scaling across 20 plants, we will meet you where you are. Start with a conversation. No pitch decks. No vendor lock-in. Just engineers who understand manufacturing.

APPWRK Clients' Success Stories
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