What exactly is TaaS-MI and how is it different from traditional MES systems?
Taas-MI
TaaS-AITM Manufacturing Intelligence & Collaboration
The Operational Engine for Traceability
Imagine knowing the real-time status and predicted completion time of every job, order, and component in your production line. TaaS Manufacturing Collaboration extends your operations for direct collaboration with your customers and suppliers. The TaaS-AI solution replaces outdated Manufacturing Execution Systems (MES) by providing Operational Intelligence across multi-site global operations. It transforms reactive monitoring into predictive foresight across your entire value chain, driving true end-to-end traceability and collaboration with customers and suppliers.
Problem Statement VS The OmniTaaS Advantage
We directly address the critical pain points created by manual processes and legacy systems, providing a clear path to actionable and operationally useful digital transformation.
Operational Blind Spots
Manual tracking prevents real-time insight into work-order exceptions, on-time delivery, and resource utilization.
Automated Real-Time Operational Intelligence
Gain instant visibility into job status across all operations. Monitor exceptions, bottlenecks, efficiency, and productivity to ensure over 99% on-time delivery.
Supplier Management
Time-consuming, inaccurate reports, creating on-time delivery anxiety and ongoing operational crises management by the customer.
Collaborative Manufacturing
Eliminate customer anxiety by providing real-time transparency on order delivery schedule, status, and exceptions with TaaS digital-twin directly to customer operations.
Legacy MRP
Operationally disconnected systems are unable to accurately forecast delivery schedules, losing revenue, and increasing stock-outs and safety stock.
Actionable Digital Transformation
TaaS-AI applications unify existing systems with real-time operational intelligence through powerful IoT tracking of work-orders to improve business process efficiencies.
Fraud & Audit Nightmares
Lack of supplier visibility leads to fraud, unexpected exceptions, and incomplete records for auditable genealogy and warranty returns.
Traceability Intelligence
Track BoM parts with operational traceability to achieve highest quality, quickly determine fault root-causes, eliminate fraud and optimize return and recall costs.
Reactive Maintenance
Maintenance by schedule, not by actual usage, leads to unexpected downtime and unnecessary maintenance costs.
Intelligent Maintenance
Drive significant cost savings by optimizing maintenance & calibration schedules based on actual asset utilization to eliminate unexpected downtime.
Manufacturing Blind Spot
Manual status capture, lack of product pedigree, and inaccurate Finished Goods (FGI) and WIP inventory forecasts.
Automated Production Status
High integrity “automated” shop-floor status and end-to-end supply chain visibility. Integrated product pedigree (EPC compliant) without the need to train staff.
On-Premise Burden
Managing on-premise infrastructure drains IT resources, increases support costs, and introduces security risks.
Secure Private Cloud SaaS
TaaS-AI has pioneered Premise-on-CloudTM secure IoT services providing best-in-class security and operational uptime on Azure and Oracle cloud platforms.
Key Platform Features at a Glance
Our solution provides a comprehensive set of features, validated by over 20 years of industrial experience, built to eliminate guesswork and drive financial accountability.
Real-Time Automated Workorder Tracking
IoT-powered (RFID/RTLS) tracking for improved on-time delivery, accurate forecasting, and proactive exception monitoring.
Operational Cost Analysis
Task-level financial analysis, tracking real-time bottleneck costs and providing item-level analytics for BoM, WIP, and FGI.
Mobile Visibility Service (MVS)
Empowers floor operators with mobile access to manage tasks and update work orders directly at the point of action.
Complete Part Pedigree & Traceability
Item-level serialization & genealogy (BoM, reports) for delivery forecasting and full traceability from goods receipt to FGI.
Real-Time Collaborative Manufacturing
Automated shop-floor collaboration with supplier reports, workorder exception alerts, and integrated daily operating reports (supplier/customer).
Configurable Dashboards & Reports
Customizable dashboards, reports, and exception alerts (email/SMS) providing actionable insights for managers and external partners.
Business Process Digital Twin
Real-time digital twin for shop-floor collaboration, tracking operational efficiency, managing pick/kitting, and monitoring workflows to forecast delivery exceptions.
Configurable Digital Workflow
Define, map, and manage complex operational workflows (WIP) with no code, accelerating digital transformation for BPO and manufacturing.
Key Business Benefits
The TaaS-AI solution drives operational efficiency and competitive advantage by replacing reactive management with real-time, predictive intelligence.
Financial & Quality ROI
- Maximized Operational ROI: Optimize machine, labor, and resource allocation based on real-time data, significantly reducing overhead and maintenance costs.
- Minimized Waste & Recall Risk: Rapidly isolate root causes with high-integrity genealogy, reducing material spoilage, rework costs, and executing faster, targeted recalls if necessary.
Operational Efficiency & Speed
- Proactive Decision-Making: Move from reactive firefighting to predictive control. Real-time insights allow teams to resolve potential bottlenecks before they impact production lines.
- Boosted Throughput: Eliminate non-value-added waiting time and synchronize component deliveries, achieving an 18% reduction in bottlenecks and higher production accuracy.
Risk Mitigation & Compliance
- Automated Process Compliance: Strengthen security and regulatory adherence (e.g., FDA, FAA) by enforcing sequential process steps and automatically generating audit-ready history.
- Guaranteed On-Time Delivery: Achieve over 99% on-time delivery by replacing static schedules with dynamic, predictive forecasts that account for real-time exceptions.
Platform Value & Collaboration
- Seamless Supply Chain Synchronization: De-risk your value chain by securely sharing real-time WIP status with partners, ensuring faster responses to supply disruptions.
- De-Risked Deployments: Utilize our Digital Twin simulations to test new line configurations and workflows virtually before physical implementation, ensuring smooth rollouts.
Deep Dive: The Three Pillars of Operational Intelligence
The Manufacturing Intelligence solution is built upon three integrated pillars, ensuring traceability, predictability, and connectivity across all operational stages.
Pillar 1: High-Integrity WIP & Genealogy
End-to-End Traceability
Track the complete journey from Raw Materials Receipt and Kitting to final assembly, creating an unbreakable Digital Thread for every unit.
Automated Pedigree
Generate instant, audit-ready Genealogy Reports linking every BoM component to the specific operator, machine, and process time utilized.
Process Enforcement
Use RFID/IoT to validate that mandatory steps (e.g., curing time, quality checks) are completed before a job can logically move to the next station.
Pillar 2: Predictive Optimization & Cost Analysis
Predictive Bottleneck Detection
The proprietary AI engine analyzes accumulation points and cycle time variances to forecast delays before they stop the line.
Operational Cost Analysis
Bridge the gap between operations and finance by tracking the real-time cost impact of dwell time, rework, and resource inefficiency at the task level.
Digital Twin Simulation
Use EdgeView to run "what-if" scenarios on your workflows, validating new line configurations virtually to de-risk changes.
Pillar 3: Supply Chain Synchronization & Connectivity
Integrated Collaboration
Provide suppliers and customers with secure, real-time dashboards to view the status of their specific orders, reducing anxiety and manual reporting.
Enterprise Integration
Connect seamlessly with existing ERP, MRP, and WMS systems via open APIs to ensure operational data drives higher-level business planning.
Mobile Empowerment (MVS)
Extend operational control to the edge, allowing operators to view tasks, report exceptions, and manage WIP flow directly from handheld devices.
Industry Applications: See Asset Intelligence in Your Sector
As an industry-agnostic framework, the TaaS-AI solution is built to master any operational environment. Click your industry below to see how Manufacturing Intelligence solves your unique traceability and compliance challenges.
Predictive Production & Supply Chain Integrity
Move beyond reactive MES. Our solution creates a real-time digital twin of your entire value chain—from raw materials to finished goods—enforcing strict process adherence while using predictive AI to guarantee on-time delivery.
Key Use Cases
- Automated Real-Time Operational Intelligence: Eliminate manual blind spots by instantly identifying bottlenecks, job status exceptions, and productivity dips to ensure over 99% on-time delivery.
- Validated Process Adherence: Enforce strict sequential operations and mandatory dwell times to prevent costly rework and scrap.
- High-Integrity Genealogy: Automated, immutable pedigree linking every BoM part, operator, and machine for instant auditability.
- Operational Cost Analysis: Track real-time financial impact of WIP dwell time and bottlenecks at the task level.
- Supplier Synchronization: Securely share real-time WIP status with partners to de-risk inbound supply and guarantee customer delivery schedules.
Defense-Grade Security & As-Built Pedigree
In Aerospace & Defense, transparency is a mission-critical requirement. We utilize hybrid RFID/barcode serialization to provide end-to-end visibility for sensitive, high-value components, ensuring strengthened security, audit-ready compliance, and absolute production reliability.
Key Use Cases
- Sensitive Component Serialization: End-to-end, real-time tracking of high-value assets using hybrid RFID and barcode technologies.
- Multi-Tier Supplier Traceability: Audit-ready genealogy extending deep into the supply chain to validate provenance and prevent counterfeit parts.
- Integrated Compliance: Automated tracking reduces audit failures and enforces strict adherence to FAA, DoD, and international regulations.
- Digital Twin Simulation: Validate complex assembly workflows virtually before physical implementation to ensure first-pass production reliability.
- Secure Chain of Custody: Strengthened security monitoring for regulated items as they move through unsecured operational zones.
JIT Sequencing & Digital Twin Orchestration
In automotive manufacturing, seconds matter. We leverage Digital Twins and real-time IoT to orchestrate complex build-to-sequence workflows, aiming for over 99% on-time delivery through predictive scheduling and enhanced global supply chain collaboration.
Key Use Cases
- Digital Twin Scheduling: Simulate production routes and utilize predictive scheduling to optimize resource allocation and reduce costs.
- End-to-End Vehicle Genealogy: Complete traceability intelligence linking every BoM part from Tier 1 suppliers to the final Finished Good (FGI) VIN.
- Mobile WIP Monitoring: Empower floor managers with real-time visibility into work-order status and warehouse inventory via mobile devices.
- Tier 1 Supplier Synchronization: Enhance collaboration across global supply chains to reduce production downtime and ensure Just-in-Time (JIT) accuracy.
- Predictive Exception Management: Automated monitoring of deviations to proactively resolve bottlenecks and guarantee delivery schedules.
Patient-Ready Operations & Compliance
In healthcare, operational delays can impact patient outcomes. We leverage item-level serialization and real-time geo-location to orchestrate hospital workflows, ensuring critical medical assets and consumables are compliant, available, and instantly ready for patient care.
Key Use Cases
- Serialized Consumable Tracking: Trace high-value implants and consumables from receipt to patient use for precise recall readiness and billing accuracy.
- Mobile Task & Compliance Monitoring: Empower clinical staff with MobileView to manage operational tasks and verify location-based compliance protocols in real-time.
- Automated Regulatory Audit Trails: Maintain immutable digital records of equipment handling and sterilization cycles for JCI and FDA validation.
- Expiry & Waste Reduction: Proactive alerts for expiring consumables and misplaced assets significantly reduce waste and ensure guaranteed availability.
- Operational Flow Optimization: Reduce patient wait times by synchronizing asset readiness with patient admission and procedure schedules.
High-Velocity Synchronization & Yield
In high-tech manufacturing, speed and precision are paramount. Our solution utilizes hybrid RFID/barcode tracking to synchronize component deliveries with production needs, maximizing throughput while providing the granular traceability needed to reduce material loss and improve yield.
Key Use Cases
- Component Serialization: Trace individual high-value components and tools to isolate defects and optimize yield.
- Hybrid Real-Time Job Tracking: Automate WIP monitoring using both RFID and barcode systems to ensure 100% production accuracy at high speed.
- Inbound Supply Synchronization: Integrated logistics management ensures the right components arrive exactly when needed, preventing line-down situations.
- Proactive Deviation Alerts: Real-time exception monitoring instantly flags process deviations, allowing for faster response to disruptions.
- Warranty Defense: Maintain immutable "As-Built" records for every serial number to defend against unwarranted bulk returns.
Process Integrity & Real-Time Economics
For continuous flow and batch industries, efficiency is everything. We utilize a Business Process Digital Twin to track real-time performance by task, ensuring strict recipe adherence while providing the operational cost visibility needed to improve predictability and decision-making.
Key Use Cases
- End-to-End Pedigree: Complete, automated genealogy linking raw materials from goods receipt through every process stage to final dispatch.
- Operational Cost Analysis: Track real-time financial impact of energy, material, and dwell time on WIP and Finished Goods (FGI) costs.
- Predictive Bottleneck Reduction: Utilize real-time analytics to identify process slowdowns instantly, significantly improving throughput.
- Automated Workflow Integrity: IoT-driven tracking ensures mandatory process parameters (temperature, mixing time) are met before releasing batches.
- Intelligent Maintenance: Reduce calibration and repair costs by basing maintenance schedules on actual process utilization rather than fixed intervals.
Cold Chain Integrity & Perishable Traceability
In the perishable goods sector, time and temperature determine value. We utilize Digital Twins and real-time RFID/IoT tracking to provide end-to-end visibility across production and packaging lines, ensuring strict cold chain adherence and maximizing shelf-life.
Key Use Cases
- Predictive Shelf-Life: Utilize Digital Twin models to predict finished good shelf-life based on actual production and storage environmental data.
- Cold Chain Deviation Alerts: Real-time, exception-based alerts instantly flag temperature or process deviations before spoilage occurs.
- End-to-End Real-Time Tracking: Seamless RFID/IoT monitoring of ingredients and finished goods from raw material receipt through production to logistics.
- Instant Recall Readiness: Accelerate recalls by tracing contaminated batches to every specific finished pallet in minutes, not days.
- Automated Safety Compliance: Replace manual logs with immutable, sensor-based audit trails for HACCP and regulatory standards.
Next Steps: Unlock Your Predictive Potential
Ready to replace manual WIP execution with predictive operational intelligence?
Achieve an 18% reduction in WIP bottlenecks and guarantee higher customer satisfaction.
Frequently Asked Questions!
