Smarter Factories. Less Downtime. More Output.
Industrial automation backed by 15+ years of engineering depth
We combine AI, industrial IoT, and deep engineering expertise to modernise manufacturing operations. Whether you are running legacy PLCs or building a new smart factory from scratch, we deliver automation that works on the shop floor — not just in demos.
What We Offer
Comprehensive solutions tailored to your specific needs and goals.
Predictive Maintenance
Replace reactive and scheduled maintenance with AI-driven prediction. Know 48–72 hours before a machine fails — and fix it before it costs you a production run.
- Vibration, temperature, and current sensor integration
- Time-series anomaly detection models
- Failure prediction with configurable lead time
- Maintenance scheduling optimisation
AI Vision Quality Control
Replace manual visual inspection with computer vision that catches defects at line speed — consistently, without fatigue. Runs on standard industrial cameras.
- Defect detection and classification
- Dimensional measurement and tolerance checking
- Surface and texture anomaly detection
- Multi-camera line integration
SCADA & PLC Integration
Connect your OT environment to modern data infrastructure without replacing existing equipment. We bridge legacy PLCs, SCADA systems, and new IIoT platforms.
- OPC-UA / Modbus / Profinet data extraction
- Legacy PLC data bridging
- Real-time data pipeline to cloud or on-premise
- SCADA dashboard modernisation
Digital Twin Development
Build a live virtual model of your production environment. Simulate changes, optimise throughput, and test process improvements before touching the physical line.
- Production line digital modelling
- Real-time sensor data synchronisation
- Throughput and bottleneck simulation
- What-if scenario testing
Production Process Optimisation
Apply AI and data science to your production data to find the hidden levers — shift patterns, machine parameters, material batches — that drive yield and OEE improvements.
- OEE baseline measurement and analysis
- Root cause analysis of quality and downtime
- Machine parameter optimisation
- Scheduling and sequencing optimisation
IIoT Infrastructure & Connectivity
Design and deploy the sensor, network, and data infrastructure that makes everything else possible. From sensor selection to secure cloud connectivity.
- Sensor selection and installation planning
- Industrial network design (OT/IT segmentation)
- Edge compute deployment
- Secure cloud connectivity
Factory Automation That Pays For Itself
Less downtime. Fewer defects. More output. Measurable within months.
- Works with your existing PLCs and SCADA — no rip-and-replace required
- Predictive maintenance projects typically pay back in 3–6 months
- AI vision QC achieving 98%+ defect detection rates in production
- OT security hardening included — we never leave your factory exposed
- On-site delivery by senior engineers, not offshore juniors
Key Benefits
Reduce Unplanned Downtime
Predict failures before they happen. Stop losing production runs to avoidable breakdowns.
60–70% downtime reductionEliminate Defect Escapes
AI vision catches what manual inspection misses — consistently, at line speed.
98%+ defect detection rateImprove OEE
More output from the same equipment, shifts, and floor space.
10–25% OEE improvementSecure OT Connectivity
Connect your factory safely — OT/IT segmentation and IEC 62443 principles built in.
Zero OT security incidents post-deploymentOur Process
A proven approach that delivers results consistently.
Site Assessment & Discovery
1–2 weeksWe visit or remotely assess your facility — understanding your processes, existing equipment, data availability, and the biggest pain points costing you money right now. No assumptions, no generic proposals.
Solution Design
1–2 weeksArchitecture, technology selection, integration points, and a fixed-price scope. We design around your existing infrastructure — not around what we prefer to sell.
Build & Integration
6–16 weeksDevelopment, model training, hardware integration, and staged testing — first in isolation, then connected to live production. We minimise disruption to your running operations.
Go-Live & Handover
2–3 weeksControlled production rollout, operator and maintenance team training, documentation, and 30 days of post-launch support. We do not disappear at go-live.
Why Automate Your Factory With Us?
We are engineers first. We have designed systems that run under real production pressure — not consultants who have read about manufacturing. Our team includes specialists with backgrounds in industrial controls, applied ML, and OT security.
We Work With What You Have
Legacy PLCs, old SCADA systems, no data historian — we have seen it all. We design solutions around your existing infrastructure, not around what we would prefer to install.
OT Security Built In
We never connect OT to IT without proper segmentation and hardening. IEC 62443 principles applied as standard — not an add-on.
On-Site When It Matters
Factory automation cannot be done entirely remotely. We are on-site for assessment, integration, and go-live. UK and Pakistan-based team available for UK, EU, and Middle East engagements.
ROI Before We Start
We calculate expected return before you commit to a project. If the numbers do not make sense, we will tell you. We have walked away from projects that would not deliver measurable value.
Real-World Use Cases
Examples from projects we've delivered — with real challenges, solutions, and outcomes.
Challenge
Unplanned CNC spindle failures averaging 3 per month, each costing £25k+ in lost output
Solution
Sensor-based predictive maintenance with 48-hour failure prediction window
Results
Challenge
8–12% defect escape rate on stamped parts causing customer returns and OEM penalties
Solution
Multi-camera AI vision system trained on 6 defect categories, integrated with rejection gate
Results
Challenge
No visibility into production line performance across 3 sites — all data on paper
Solution
IIoT retrofit connecting existing equipment, centralised OEE dashboard, shift reporting automation
Results
Challenge
High scrap rate with no understanding of which process parameters caused it
Solution
Process data collection, correlation analysis, and parameter optimisation model
Results
Case Studies
Real results from real projects.
Predictive Maintenance for CNC Machining Lines
Unplanned CNC spindle failures causing 4–6 hour production stops, averaging 3 incidents per month. Each incident costing £25k+ in lost output and emergency maintenance.
Results
AI Visual Inspection for Automotive Components
Manual visual inspection missing 8–12% of surface defects on stamped metal parts, leading to customer returns and penalty charges from OEM clients.
Results
What Our Clients Say
"We had been told by two other vendors that our legacy PLCs could not be connected to modern analytics without replacing the whole line. DevSimplex connected them in 6 weeks without touching a single PLC. The data we now have access to changed how we run the business."
"The vision system catches defects our inspectors were missing for years — and it never has a bad day. Within a quarter our customer return rate was zero. The ROI calculation was straightforward."
Frequently Asked Questions
Do you work with legacy equipment and old PLCs?
Yes — this is most of what we do. Most factories are not greenfield. We have connected 20-year-old Siemens, Allen-Bradley, and Mitsubishi PLCs to modern data infrastructure without replacing or reprogramming them. We use OPC-UA, Modbus, and protocol bridging to extract data from equipment that was never designed to share it.
Will this disrupt our production while you implement?
We design specifically to minimise production disruption. Sensor installation is typically done during planned maintenance windows. Software systems are tested in parallel before cutover. We have never caused an unplanned production stop during an implementation.
What data do you need to get started?
It depends on the application. For predictive maintenance, we ideally want 6–12 months of sensor or historian data — but we have built working models with 8 weeks of data. For vision QC, we need a sample of defective and good parts to build a training set. For process optimisation, we need production and quality records. The site assessment tells us what you have and what is feasible.
Do we need to move our data to the cloud?
No. We build for your constraints. Many manufacturing clients require on-premise or air-gapped deployments for OT security reasons. Our predictive maintenance and vision systems can run entirely on edge hardware with no cloud dependency. Cloud is an option, not a requirement.
What is OEE and how much can you realistically improve it?
OEE (Overall Equipment Effectiveness) measures availability, performance, and quality as a combined percentage. World-class is around 85%. Most manufacturers we work with start between 55–70%. Our projects typically deliver 10–25 percentage point improvements — primarily through reducing unplanned downtime and quality losses. We calculate a realistic baseline and target before starting.
How long before we see ROI?
Predictive maintenance and vision QC projects typically pay for themselves within 3–6 months because the cost of the problem they solve is immediate and measurable. Process optimisation and digital twins have longer payback — typically 6–18 months. We calculate expected ROI as part of the scoping process and only recommend projects where the numbers make sense.
Do you handle OT cybersecurity?
Yes. Any time we connect OT equipment to IT networks or the internet, we design OT/IT network segmentation, secure remote access, and follow IEC 62443 principles. We also offer standalone OT security assessments. Connecting a factory to the internet without proper OT security hardening is one of the most common and dangerous mistakes we see.
Can you work with our existing MES or ERP?
Yes. We have integrated with SAP, Oracle, Infor, Epicor, and several custom MES platforms. If it has an API or a database we can reach, we can connect to it. For systems with no integration capability, we have built middleware layers that bridge the gap.
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Let's discuss how we can help transform your business with factory & industrial automation.