Manufacturing & Industry 4.0

Powering Manufacturing's Evolution to Industry 4.0

From legacy upgrades to AI-ready infrastructure – IPS helps manufacturers evolve into fully connected, data-optimized operations with intelligent automation, digital twins, and seamless ERP integration.

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Understanding the Industry

With global supply chain disruptions, rising cost sensitivity and a shift towards data-driven, predictive operations, the manufacturing industry is under immense pressure to modernise. Yet many manufacturers still struggle with legacy systems, siloed data, inefficient tooling processes and limited visibility of production performance.

At IPS, we support manufacturing companies in laying the groundwork for smart, connected and resilient operations. Our teams deliver custom software and IT solutions that enable real-time machine monitoring, predictive maintenance, automated quality control and robust tool lifecycle management. We transform complex production environments into agile, future-ready ecosystems, offering everything from ERP integration and CAD/CAM-linked simulations to cloud-based product data platforms and intelligent IoT architectures.

Whether you're looking to digitise tool logistics, manage hot/cold sensor data flows, automate service workflows, or simulate cutting processes in 3D, we provide the systems and expertise to power your Industry 4.0 evolution.

Typical Challenges We Solve in Manufacturing & Industry 4.0

IPS has decades of experience in custom development and system integration. We understand the complexities of modern production environments, including tool mismanagement, delayed jobs, disconnected machines, and data overload. We can help you to transform your business with precision, structure and speed.

CHALLENGE 1

Managing Real-Time Data from Fragmented IoT Landscapes

The challenge

Manufacturers rely on a variety of sensors and machine interfaces that have inconsistent data formats and protocols. This makes it difficult to develop systems that provide real-time visibility and historical reporting without overloading infrastructure.

Our approach

We consolidate sensor data into a unified model, enabling dynamic hot and cold data flows through plug-and-play integration. Real-time (hot) pipelines drive alerts, dashboards and anomaly detection, while cold data workflows enable long-term storage, compliance reporting and analytics — all of which are integrated with your existing infrastructure. This architecture enables you to respond instantly to operational events while maintaining a solid foundation for insights and improvement.

CHALLENGE 2

Inefficient Tool Selection and Setup Processes

The challenge

Selecting the right tools and machining paths for new components often involves trial and error, resulting in wasted time, materials and resources. This is particularly true in cutting tool manufacturing, where it affects product quality, lead times, and profitability.

Our approach

We use a combination of rule-based logic, AI-driven optimisation and CAD/CAM integration to automate the selection of the most suitable tools and toolpaths based on 3D model data. Advanced simulations help to identify bottlenecks, predict tool life and validate machining steps before they reach the production line. This reduces the need for trial runs by up to 40% and enables faster, smarter decisions without disrupting production.

CHALLENGE 3

Lack of Insight into Cutting and Machining Performance

The challenge

Without transparent processes, it is difficult to predict outcomes, optimise material removal and simulate the impact on the quality of the final part.

Our approach

We implement advanced 3D simulation tools that compare process output to digital product specifications, thereby cutting prototyping costs by up to 35% and improving the precision of CNC and metalworking operations.

CHALLENGE 4

AI Integration Across Production Systems

The challenge

Although many factories are already exploring the use of AI in certain fields, poor data quality and fragmented infrastructure often prevent its effective implementation.

Our approach

We prepare your environment for AI by connecting operational systems, structuring datasets and deploying machine learning (ML) components where they will add real value, such as for predictive maintenance, anomaly detection or inventory forecasting.

CHALLENGE 5

Tool Loss, Misuse, and Resource Inefficiencies

The challenge

Operators spend up to 20% of their time searching for tools, while over 50% of tooling resources remain unused, resulting in delays, excess inventory and unnecessary costs.

Our approach

We implement end-to-end tooling logistics solutions, including automated tool storage close to workstations, real-time tracking of tool location and usage, and dashboards for monitoring availability and consumption. Target stock levels and smart purchasing thresholds allow systems to trigger automatic reorders. This ensures that tools are where they are needed when they are needed, while reducing excess inventory and manual handling.

CHALLENGE 6

Dealing with Global Supply Chain Complexity

The challenge

Volatile global supply chains require flexible production planning and the ability to reconfigure quickly, especially when procurement, shipping or warehousing are disrupted.

Our approach

We develop modular systems that facilitate dynamic bill of materials (BOM) management, vendor integration, and scenario-based production planning, enabling you to respond swiftly to disruptions without overhauling your core ERP system.

CHALLENGE 7

Smart Tool Lifecycle Management and Remote Servicing

The challenge

For manufacturers deploying smart tools, managing firmware versions, tracking tool lifecycle data and offering remote servicing has become critical. Without automation, the risk and effort involved in version mismatches, manual updates and opaque service histories increases.

Our approach

We develop customised platforms for the management of the lifecycle of smart tools, including version-controlled firmware portals, automated flashing workflows and remote diagnostics. Tool data is extracted directly from embedded chips and synchronised with your tool catalogue for real-time traceability. Secure remote access enables service teams to debug and update tools remotely, thereby increasing efficiency, transparency and customer satisfaction.

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Weitere Branchen, die wir bedienen

Automobilindustrie

Innovation mit intelligenten, vernetzten und nachhaltigen Lösungen vorantreiben.

Energie

Gestalten Sie die Zukunft der Energie mit effizienten, klimafreundlichen Innovationen.

Versicherung & Gesundheitswesen

Digitalisierung von Pflege und Versicherung mit intelligenten Lösungen.

Fertigung & Industrie 4.0

Optimierung der Produktion mit KI, Automatisierung und datengesteuerter Effizienz.

Logistik

Verbesserung der Logistik durch Automatisierung und operative Agilität.

Fintech & Finanzdienstleistungen

Transformation des Finanzwesens mit KI, Cloud und fortschrittlicher Analytik.

Entdecken Sie unsere Fallstudien

Contact us

Looking to digitize your factory, scale your ERP, or unlock AI in production? Our experts are ready to help — just fill out the form and we’ll be in touch.