INDUSTRY
Manufacturing & Industry 4.0
From legacy plant to intelligent factory.
Modern manufacturers are under relentless pressure to increase throughput, reduce waste, and maintain stringent quality standards - all while contending with ageing equipment and a shrinking skilled workforce. Legacy systems that once served production well are now data silos, unable to communicate with newer line controllers, ERP platforms, or cloud analytics layers.
At the same time, regulatory requirements around energy consumption, workplace safety, and traceability are tightening across DACH and the broader EU. Manufacturers who fail to digitise risk falling behind competitors who can detect defects in real time, predict machine failures before they cause downtime, and optimise energy use across entire plants.
The path to Industry 4.0 is not a single technology purchase - it is a disciplined engineering programme that connects sensors, machines, and enterprise systems into one coherent intelligence layer. That is exactly what Tavlo builds.
Use Cases
Predictive Maintenance for Rotating Machinery
Continuously monitor vibration, temperature, and acoustic signatures to forecast bearing and motor failures weeks in advance.
Visual Quality Inspection at Line Speed
Camera-based deep-learning models detect surface defects, dimensional deviations, and assembly errors without slowing production.
AI-driven Production Scheduling
Optimise job sequencing, changeover timing, and resource allocation using constraint-aware ML models.
OEE Dashboards in Real-time
Aggregate availability, performance, and quality metrics from every line into live dashboards accessible plant-wide.
Digital Twin of Production Lines
Build a virtual replica of your production environment to simulate changes, test scenarios, and validate improvements before deployment.
Worker Safety Monitoring
Use computer vision and IoT wearables to detect unsafe behaviours, restricted zone breaches, and PPE compliance in real time.
Standards
Common questions
What AI use cases does Tavlo deliver for manufacturers?
Predictive maintenance for rotating machinery, visual quality inspection at line speed, AI-driven production scheduling, real-time OEE dashboards, digital twins of production lines and worker safety monitoring - connected to the MES, ERP and control systems you already run.
Can Tavlo work with our existing machines and legacy systems?
Yes. Most industrial environments are brownfield, and we design for that reality: we retrofit legacy equipment with modern sensors, bridge protocols such as OPC UA and MQTT, and connect decades-old machines to modern analytics instead of replacing them.
Does our production data have to go to the cloud?
No. We deploy to edge hardware inside the plant where latency, IT policy or data protection demand it, and to the cloud where that is the better fit. For predictive quality and maintenance, our Tavlo Industrial AI product runs fully on-premises.
Which standards does Tavlo's manufacturing work follow?
Our manufacturing solutions are built around ISO 9001 and ISO 14001 management standards, OPC UA and IEC 61131 for industrial communication and control, and IEC 62443 for industrial cybersecurity.
How do we start a manufacturing AI project with Tavlo?
Write to contact@tavlo.tech and describe the line or process you want to improve. We respond within two business days and typically start with a 30-minute call - for predictive maintenance we can demonstrate a live system. Implementation details are shared under NDA.
Your next intelligent system starts here.
Whether you're in DACH or beyond, we're ready to deliver.