Industrial Automation
Turning legacy plants into self-learning factories with PLC/SCADA modernisation, IIoT and Digital Twins.
Industry Overview
AISYS delivers end-to-end Industrial Automation solutions for discrete and process manufacturing plants. We modernise legacy PLC/SCADA infrastructure, deploy IIoT retrofits on ageing assets, and build Digital Twins that let operators simulate changes before touching the shop floor.
Our reliability-first approach combines cognitive RPA, computer-vision quality inspection, and predictive maintenance models — delivering measurable OEE uplift, reduced unplanned downtime, and faster changeovers across every site we commission.
Key Highlights
Higher Throughput
Workflow orchestration eliminates bottlenecks across shop-floor operations.
Predictive Uptime
ML models forecast equipment failure 7–14 days before breakdown.
OEE Improvement
Average 15–25% OEE uplift within the first 6 months.
Digital Twin Ready
Every line is mirrored in a live virtual replica for simulation and training.
What We Deliver
- PLC/SCADA modernisation & migration
- IIoT retrofits on brownfield machinery
- Digital Twin creation (discrete + process)
- Predictive Maintenance (vibration, thermal, acoustic)
- Computer-Vision quality inspection at line speed
- MES ↔ ERP ↔ SCADA integration
- Intelligent Process Automation (IPA) with human-in-loop
Use Cases
Process Plants
Chemical, pharma, cement and steel facilities leveraging real-time OEE monitoring and advanced process control.
Manufacturing
Automotive, FMCG and electronics lines with computer-vision inspection and robotic pick-and-place cells.
Warehousing
Automated storage/retrieval, AMR fleet orchestration and WMS ↔ ERP real-time sync.
Clients We Serve
Representative Tech Stack
Frequently Asked
Can you work with existing legacy PLCs?
Yes. Our brownfield retrofit methodology adds an IIoT gateway layer without disrupting the existing control logic — you keep your current PLC investment and gain real-time cloud telemetry.
What ROI should we expect?
Typical deployments achieve 15–25% OEE improvement and 20–40% reduction in unplanned downtime within 6–9 months.
Do you handle commissioning on-site?
Yes. AISYS owns end-to-end delivery including field commissioning, operator training, SAT/FAT and post-go-live support.
Planning a Industrial Automation initiative?
Our sector specialists respond within one business day. No obligations, no fluff.
Industrial Automation industry solutions Delivered from Dilsukhnagar, Hyderabad, India
AISYS Engineering operates from 13-17-85, 2nd floor, Annapurna Complex, Dilsukhnagar, Hyderabad, Telangana 500060, India. Teams based in Dilsukhnagar work directly with clients across Hyderabad, Telangana and the wider India industrial corridor, with programmes routinely shipping to international customers.
Being anchored in Hyderabad — a recognised deep-tech and R&D hub — gives AISYS Engineering fast access to precision-manufacturing partners, calibration labs, semiconductor supply chains and the university research ecosystem across Telangana. That local density is what allows short iteration cycles, on-site FAT / SAT and reliable hardware-in-the-loop programme execution.
- On-site programme reviews and integration support across Hyderabad and Telangana
- Cross-vertical engineering teams co-located in Dilsukhnagar for tight iteration
- Delivery experience across India, supplemented by global remote collaboration
Talk to AISYS Engineering about Industrial Automation industry programmes
Book a scoping call with our Dilsukhnagar, Hyderabad engineering team and get a tailored delivery plan for your programme in India.
Contact AISYS Engineering →