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AI for Manufacturing That Actually Scales

 

Join the 15% of manufacturers who move beyond AI pilots and achieve production-grade results.

While 85% of AI pilots stall and never deliver measurable ROI, Digica helps manufacturers, with production-ready AI proven in 300+ deployments. See real impact in as little as 90 days.

Forged in production. Proven under pressure. Delivered when it matters.

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What Makes Digica Different

  • Rapid ROI - Measurable payback in 3–6 months, not years.

  • Edge-First Deployment - Seamless integration with legacy OT systems, minimal disruption.

  • Synthetic Data & Hybrid Data Strategies - To overcome gaps in real data and build robust models.

  • IP Ownership & Flexibility - You own the data, models; no lock-in.

  • Proven Track Record - 300+ live deployments in manufacturing, delivering results under real-world constraints.

Why Manufacturers Partner with Digica

We get it, manufacturing leaders are up against:
  • High failure rates - 85% of AI pilot projects never scale to full production.
  • Complex, legacy OT environments - Integrating with SCADA, DCS, PLCs, etc., can stall or sink projects.
  • Data & skills gaps - Labelled data is scarce; internal AI expertise often thin.
  • ROI demands - Stakeholders want clear, measurable returns now—not vague promises for years ahead.

Digica solves all of those by delivering operational AI systems that are scalable, practical, and built for your manufacturing floor.

Core AI Solutions & Impacts

  • Quality Control & Defect Detection - Minimize defects by up to 40% in 3–6 months.

  • Predictive Maintenance & Asset Optimisation - Avoid costly downtimes (sometimes upwards of £47,000/hour) through predictive analytics.

  • Edge-First Industrial Automation - Real-time detection and control, reducing latency and errors.
  • Smart Factory & Digital Twins - Improve efficiency: reduce costs by 5–7%, cut energy use by 30%.

FAQ

Frequently Asked Questions

Show all FAQs
How soon can I see results?

Many clients begin seeing measurable improvements (defect reduction, fewer breakdowns, etc.) within 3-6 months from solution deployment.

Do I need lots of labelled data to get started?

No. We combine what data you have with synthetic data generation and hybrid approaches. Even rare defects can be modeled without thousands of real-world examples.

How will this integrate with my existing OT / factory floor systems?

Our edge-first approach is designed to work with SCADA, DCS, PLCs, and most industrial control systems. We aim for minimal disruption in operations.

What if I already tried an AI pilot and it failed?

That’s exactly where Digica shines. We help you move past the “pilot graveyard”-identifying what held the pilot back, fixing the bottlenecks, and delivering production-grade solutions.

What is the cost?

It depends on the scope, but we offer Factory Health Audits and Proof-of-Concept sprints at fixed cost so you can estimate value before committing large scale investment.

How does this help with sustainability or energy goals?

Our digital twin / smart factory approaches can drive 5–7% operational cost savings and ~30% energy reductions. Plus, fewer defects & less waste support environmental goals.