SmarTwin™ takes whatever signals your plant produces — PLCs, sensors, manual entry — and turns them into the live operational picture every shift supervisor needs. 3-second refresh. 2.4M sensor events ingested per day across active deployments.
PLCs (Siemens, Allen-Bradley, Mitsubishi), OPC-UA, Modbus, MQTT, REST APIs, SAP/Oracle/Tally — plus manual entry for paper-based areas.
Availability × Performance × Quality. Per line, per machine, per product. Refreshed every 3 seconds. Visible on every shop-floor screen.
Real reason codes — bearing failure, tooling, raw material, changeover, manning. Not black-box ML guesses. Plant Heads see the truth.
Most Indian plants run OEE on weekly Excel reports. By the time a Plant Head sees Tuesday's drop, it's Friday. The shift's gone. The cause is forgotten. SmarTwin shows OEE per machine per shift, live, on the same screen as the line supervisor — close the loop in minutes, not days.
// THE PAIN
OEE numbers come weekly from a paper system. By the time we see a problem, the shift is over. The same chronic downtime causes keep showing up but nobody can isolate why because the data is aggregated to oblivion. We're plateaued at 66% OEE and don't know what to fix first.
// SUCCESS METRICS
Typical pilot — 6 to 8 weeks for a single line. We meet your plant where it is, including 1990s machines with intermittent network.
OPC-UA, Modbus, MQTT, REST APIs, SAP/Oracle/Tally, manual entry. Edge gateways for plants with intermittent network.
Time-series ingestion at 2.4M events/day per plant. Local buffering for network drops. 99.97% twin uptime.
Availability × Performance × Quality. Per line, per machine, per product, per shift, per supervisor. Drill-down anywhere.
Plant Head wall, supervisor mobile, MD scorecard. Same data, different views. Operator-tagged downtime reasons.
Availability × Performance × Quality. Per line, per machine, per shift, per product. 3-second refresh.
Operator-tagged reason codes. Pareto by frequency, duration, financial impact. No black-box ML.
Real-time scrap rate per line, per shift. Defect category drill-down. Root-cause linkage.
Actual vs target by hour, shift, day. Bottleneck detection. Constraint identification.
Industrial protocols out-of-the-box. PLC connectors for Siemens, Allen-Bradley, Mitsubishi, Omron, Delta.
On-prem buffering for plants with intermittent network. Stores 7 days of data; syncs when connection returns.
For paper-based areas. Mobile app lets operators log shift events in seconds. Multilingual.
Mobile view tailored for supervisors walking the floor. Real-time alerts. One-tap acknowledge.
Large-screen dashboard for plant-wide visibility. Auto-rotating across lines and KPIs.
Daily plant-summary scorecard delivered to MD/CEO inboxes at 09:00 IST. PDF and dashboard versions.
A-shift vs B-shift vs C-shift. Same line. Different supervisors. Why is one consistently 4 points lower?
Aggregated production data flows back to SAP, Oracle, in-house MES. No double-entry.
Indian plants. Indian OEE math. Indian shift patterns. Verified across our deployments since 2024.
Source: Wistwin internal benchmark across 12 active SmarTwin deployments, January 2024 – April 2026.
Like every Wistwin layer, SmarTwin reads from AssetTwin and feeds the intelligence layers above.
SmarTwin reads from the asset register — every sensor event is tagged to its source asset, area, unit. No AssetTwin → SmarTwin has no idea what it's measuring.
InsighTwin reads SmarTwin's raw telemetry and explains it in plain English. "OEE dropped 2 points Tuesday because Line 3 hit changeover 14 minutes late."
PredicTwin reads SmarTwin's vibration and temperature streams to forecast bearing failures before they happen.
Take the DMM Check™. Get a personalised OEE-readiness score, a benchmark against 200+ Indian plants in your sector, and the top three telemetry connectors to deploy first.
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