Unplanned downtime and quality escapes are the two most expensive problems in manufacturing. Kalp Corporate engineers the predictive AI, computer vision, and operational intelligence systems that eliminate both — turning your factory floor data into a competitive advantage.
We build manufacturing intelligence systems that integrate with real OT environments, survive factory conditions, and deliver measurable OEE improvements from day one of production deployment.
Discuss Your Factory Roadmap →IoT sensor ingestion from vibration, temperature, current, and acoustic transducers — feeding LSTM and anomaly detection models that forecast equipment failures 48–96 hours in advance, reducing unplanned stoppages by 35–50%.
Real-time defect detection for surface flaws, dimensional anomalies, assembly errors, and contamination — operating at full line speed with sub-50ms inference, 97%+ detection accuracy, and a zero-fatigue inspection rate.
Real-time Overall Equipment Effectiveness dashboards connecting SCADA, MES, and ERP data — giving shift managers, production engineers, and plant directors a single reliable view of availability, performance, and quality simultaneously.
Real-time virtual replicas of assets, production lines, or entire facilities — fed by live sensor streams for continuous monitoring, scenario simulation, and optimisation without any interruption to running production processes.
AI-driven scheduling that balances machine capacity, workforce availability, material constraints, maintenance windows, and customer due dates — reducing changeover time, WIP inventory, and late delivery simultaneously.
Real-time energy consumption monitoring at asset, line, and plant level — identifying waste, optimising consumption scheduling, and generating the ESG and Scope 1/2 emissions data that customers and regulators are now requiring.
Manufacturing AI deployments must work around running production, safety systems, and OT network constraints. Our methodology is designed for that reality from the first engagement.
Asset inventory, sensor coverage assessment, historian data quality review, OT network architecture mapping, and SCADA/MES/ERP integration analysis — building the complete picture before any system touches live infrastructure.
A focused proof-of-concept on your highest-risk or highest-cost asset — demonstrating real model performance on your actual sensor data with a production-representative setup before any broader rollout commitment.
IT/OT segmented architecture deployment, OPC-UA and historian connections, MES and ERP integration, model training on production data, and change management support for engineering and maintenance teams.
Progressive deployment across the asset fleet, model retraining as operational patterns evolve, alert threshold tuning based on maintenance team feedback, and ongoing OEE improvement reporting.
Most software companies have never worked in an OT environment. We have deployed across automotive, food and beverage, pharmaceuticals, electronics, and heavy industry — we understand the constraints.
High-frequency time-series ingestion from PLCs, SCADA historians (OSIsoft PI, Ignition, Wonderware), and direct OPC-UA server connections — handling thousands of tag streams with microsecond timestamps.
LSTM, Transformer, and Isolation Forest models for remaining useful life prediction, anomaly scoring, and change point detection — validated on hold-out failure history before any production deployment.
YOLO, EfficientDet, and custom CNN architectures for defect detection at line speed — trained on your specific product SKUs with active learning pipelines that improve accuracy continuously from production feedback.
Network segmentation, unidirectional data diodes, encrypted historian connections, role-based access controls, and IEC 62443 security framework compliance — protecting OT networks without restricting operational function.
Bidirectional integration with Siemens Opcenter, Rockwell FactoryTalk, SAP, and Oracle — closing the loop between production intelligence, work orders, quality records, and enterprise planning systems.
Containerised edge inference for vision and sensor models running on factory-floor hardware — with optional cloud synchronisation for aggregated analytics, while keeping sensitive OT data fully on-premise.
Every tool chosen for reliability in factory conditions, OT network compatibility, and the deterministic performance that manufacturing systems require.
Book a free 60-minute manufacturing technology consultation. We will assess your current OT landscape, identify your highest-value AI opportunities, and propose a deployment roadmap — no obligation to proceed.
Combine AI decision intelligence with RPA execution to automate entire business workflows end-to-end — from intelligent document intake all the way through to approvals and notifications.
AI is only as good as the data feeding it. We build the pipelines, warehouses, and governance frameworks your ML models depend on for reliable, consistent performance.
When automation requires a custom interface, self-service portal, or integration layer, our development team builds the surrounding system that makes it all work seamlessly.