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Achieve More Output Without More Headcount
Smart Factory Solutions for More Output
AI-powered manufacturing transformation that turns shop-floor data into real-time decisions and savings
AI-powered manufacturing transformation that turns shop-floor data into real-time decisions and savings
Hexaware's AI-led smart factory solutions bring manufacturing intelligence from the shop floor to the top floor, turning factory data into real-time insight and up to 50% savings across the value chain.
How Operations Managers Connect and Optimize Smart Factory Workflows via AI
Smart factory solutions connect shop-floor equipment, production data, and enterprise systems into a single AI-driven workflow, so operations managers optimize output without juggling disconnected tools. Hexaware layers non-linear, AI-native delivery on top, using engineering pods augmented by autonomous agents to keep execution consistent as workflows scale.
Cut Waste and Get More From Every Resource
Manufacturing budgets get squeezed by waste that is hard to see until it shows up in a variance report: idle equipment, excess material, time spent on the wrong priorities. Smarter planning and tighter process control give you visibility into how equipment, materials, and time are used across production, so you can act on inefficiency before it compounds. The result is lower cost per unit and fewer surprises in your budget, without adding headcount or slowing the line to find the problem.
Catch Defects Before They Reach the Line
A defect caught at final inspection has already consumed the labor, materials, and machine time it took to get there. Real-time detection and smart sampling catch problems at the source instead, so you stop paying for defects you could have prevented instead of scrapping or reworking finished product. That shift, from inspecting outcomes to catching root causes early, turns quality from a cost center into a source of margin, one prevented defect at a time, across every shift.
Improve Yield With Real-Time Process Control
Every percentage point of yield lost to variation, drift, or an undetected process shift is output you paid to produce and can’t sell. Better process control paired with real-time manufacturing intelligence means you catch that drift while it is still correctable, not after a batch is already out of spec. You get more of what you run coming out right the first time, so yield improvements show up directly in throughput and margin, without adding a shift or expanding capacity to compensate.
See Exactly Where Production Time Is Lost
Most plants know throughput could be higher; few can point to exactly where the time is going. Clear visibility into where production time is lost, changeovers, waiting, unplanned stops, replaces guesswork with evidence your team can act on immediately. You get velocity improvements backed by data instead of instinct, so throughput rises specifically where it counts, in the bottlenecks that were actually holding the line back, not the ones that simply seemed most likely.
Put the Right Information in the Right Hands
A skilled operator with the wrong information at the wrong moment still makes the wrong call. Getting the right information in front of the right person, whether on the shop floor or in the control room, at the right moment means decisions happen faster and with full context, not after a delay spent tracking down the right report. You get a workforce that spends less time chasing information and more time acting on it, which shows up in output without asking anyone to work harder.
Our engineers work in AI-native pods augmented by autonomous manufacturing agents that run an AI-driven SDLC for manufacturing: designing, building, testing, and deploying factory application code, including MES, on their own, without adding headcount to match the workload.
We modernize legacy Manufacturing Execution Systems fast, without discarding the manufacturing logic your operations already depend on, so nothing gets rebuilt from zero, and your team keeps decades of tuning.
We validate every AI recommendation against a live digital replica of your factory before it ever reaches a real production line. That practice means operators act only on insights already proven safe, and planning teams get a place to test what-if scenarios before committing resources.
Every AI recommendation we deploy is validated and auditable before it acts on your line. Human-in-the-loop approvals keep operators in authority over the process, and every decision, recommendation, and action is traceable end to end, for compliance and for trust.
We deploy AI models at the edge for shop floor automation, directly alongside your equipment, so shop-floor data turns into real-time decisions instantly, without ever waiting on a network connection back to the cloud.
Our integration engineers work across REST, JSON, Modbus, PROFINET, Siemens S7, OPC UA, and EtherNet/IP, so we bridge IT and OT without a custom build for every machine. That expertise is what lets your AI layer stay put as equipment changes underneath it.
Our AI-led managed services put autonomous manufacturing agents to work on first-line issue resolution, bringing consistent AI in factory operations day and night. We also treat adoption as part of the engagement, using a structured ROI framework.
Purpose-built to modernize legacy Manufacturing Execution Systems without discarding the manufacturing logic your operations already depend on.
Powers our AI for factory automation and managed services, putting intelligent agents to work on first-line issue resolution before problems affect production.
A single integration interface across REST, JSON, Modbus, PROFINET, Siemens S7, OPC UA, and EtherNet/IP, so equipment changes never force a rebuild of your AI layer.
A live digital replica of your factory that validates every AI recommendation before it ever reaches a real production line.
AI-powered manufacturing software, pre-trained with zero-shot forecasting, delivering value from day one, before you’ve collected your own operational data.
Digital Strategy Consulting
Accelerate digital transformation with strategies that align business goals, customer experiences, and emerging technologies to drive business impact and long-term value.
Digital Experience
Create connected digital experiences that strengthen customer engagement, improve usability, and deliver seamless interactions that increase long-term brand value across channels.
Digital Product Engineering
Accelerate innovation with agile product engineering services designed to build scalable digital products that improve efficiency, user experiences, and business growth.
Legacy Modernization
Modernize legacy systems with AI-driven strategies that reduce complexity, improve operational agility, and create scalable foundations for future business innovation.
Software Development
Build, modernize, and scale enterprise applications faster with AI-driven software development services designed to improve delivery speed, quality, and scalability.
Smart factory solutions improve manufacturing efficiency and operational visibility by connecting shop-floor data to real-time analytics and AI-driven insight. Manufacturers get visibility into cost, quality, yield, cycle time, and energy use as it happens, so inefficiencies are caught and corrected before they compound, without adding headcount to watch the numbers.
Manufacturers use IoT and AI in smart factory solutions by deploying edge AI models directly alongside equipment, so anomalies are caught in real time rather than after a failure. Predictive insight into machine health lets teams schedule maintenance before a breakdown happens, reducing the unplanned downtime that costs far more than the fix itself.
Smart factory solutions connect shop floor operations with enterprise data and analytics platforms through a single integration layer that bridges IT systems speaking REST and JSON with OT equipment speaking Modbus, PROFINET, Siemens S7, OPC UA, and EtherNet/IP, so shop-floor data reaches enterprise analytics without a custom build for every machine.
Yes. Manufacturers can deploy smart factory solutions without replacing existing production systems, because a layered, composable architecture lets you start in one area of the factory and expand without rebuilding. Legacy Manufacturing Execution Systems get modernized in place, keeping the manufacturing logic operations already depend on.
Smart factory solutions use digital twins alongside AI by creating a live digital replica of the factory, so every AI recommendation is validated against that replica before it reaches a real production line. Planning teams also use the twin to model what-if scenarios, from new product configurations to supplier or demand changes, before committing resources.
Enterprises choose Hexaware for smart factory solutions because it combines deep manufacturing domain expertise with proprietary AI platforms, including Amaze, RapidX, and Tensai, built specifically for factory environments. That combination gives manufacturers a single partner for strategy, engineering, and managed operations, instead of stitching together point solutions from multiple specialist vendors.
Achieve More Output Without More Headcount