UK Manufacturing Software & Services

Virtual Twin gives Digital Insight for Optimized Production

A Virtual Twin gives digital insight into your factory, capturing real conditions through 3D scanning and interactive visualizations. This enables teams to identify hidden obstacles, simulate layout changes, and optimize workflows before making physical changes, reducing risks and improving operational efficiency.

Production Challenges Solved by a Virtual Twin

Many factories face hidden obstacles that cause inefficiencies, delays, and errors. A Virtual Twin helps you overcome these challenges by providing a complete, interactive digital representation of your facility:

• Hidden problem areas: Identify inefficiencies before they become costly. Engineering & Planning benefit from faster project execution, better space utilization, and fewer errors.
• Space limitations, height restrictions, and equipment conflicts: Visualize constraints and plan layout changes accurately. Production teams gain optimized workflows, real-time KPIs, and digital work instructions.
• Outdated or incomplete data: Avoid mistakes caused by old drawings or missing information. Maintenance & Facility Management can navigate systems and instructions with ease.
• Flow inefficiencies and new installations: Simulate process flows and changes digitally before implementation. Health & Safety teams can conduct virtual safety training and visualize risk areas.
• Siloed information across departments: Improve collaboration and understanding across the organization. Marketing, HR & IT can conduct virtual factory tours, workshops, and team training.

Interactive Points of Interest (PoI): Add layers of information directly to objects and areas within your Virtual Twin. PoIs can include work instructions, safety notices, inventory lists, Kaizen initiatives, or links to other systems. This turns your digital model into an actionable workspace, enabling teams to make data-driven decisions faster and more accurately.

By addressing these challenges with a Virtual Twin, you reduce project risk, accelerate planning, and unlock measurable improvements across your entire organization.

From 3D Scan to Virtual Twin

A 3D scan produces a point cloud that forms the foundation of your Virtual Twin. The data can be used to:

• Build an accurate 3D model of the facility
• Measure objects and distances with millimeter precision
• Plan layout changes and test TO-BE scenarios
• Create a digital basis for decision-making, simulation, and optimization

With a Virtual Twin, you can move objects, test changes, and optimize processes digitally before implementation – saving time, reducing costs, and increasing safety.

Value and Results

A Virtual Twin gives Digital Insight to your factory and enables:

• Data-driven production and layout optimization
• Efficient collaboration and communication
• Faster implementation of changes
• Long-term digital factory development

Would you like to know more contact Richard Gould

Tulip for Frontline Operations

Tulip for Frontline Operations digitizes production workflows, connects machines and systems, and empowers operators with real-time data. By replacing paper-based processes and disconnected tools with scalable, cloud-based applications, Tulip improves quality, traceability, and productivity across the production floor. Instead of reacting to deviations after they occur, teams gain live operational visibility, enabling faster decisions, fewer errors, and measurable performance improvements.

Eliminate Waste and Improve Performance

Manufacturers often struggle with:

• Process variability and inconsistent work methods
• Manual data entry and paper-based documentation
• Limited visibility into bottlenecks and downtime
• Slow deviation handling and quality reviews
• Siloed information across departments

Tulip for Frontline Operations standardizes work through guided digital instructions, automated data capture, and live dashboards. Operators follow structured workflows, deviations are identified instantly, and performance data becomes transparent.

The result is reduced rework, shorter lead times, improved OEE, and stronger production stability.

Built for Lean Manufacturing Across Industries

Tulip delivers value across different production environments:

Discrete Manufacturing

• Standardize assembly processes
• Improve operator performance and reduce rework
• Gain real-time insight into production KPIs and bottlenecks

Pharmaceutical Manufacturing

• Enforce SOP compliance and electronic signatures
• Accelerate batch release with review-by-exception
• Ensure data integrity and audit readiness

Medical Device Manufacturing

• Reduce training time with guided workflows
• Strengthen traceability across production
• Support validation and new product introduction

Regardless of industry, Tulip creates an environment that supports Lean principles, transparent, and continuously improving production.

Software-Driven Governance and Scalable Digitalization

Tulip is more than workflow digitization, it is an enterprise-ready software platform designed for governance and scalability.

With built-in access control, version management, approval workflows, and system integration capabilities, companies can:

• Control user roles and secure sensitive production data
• Standardize app development across sites
• Deploy templates and best practices globally
• Integrate with ERP, MES, and machine systems
• Scale digital solutions from pilot to enterprise level

This ensures that digital transformation is not only fast, but also controlled, compliant, and sustainable.

Measurable ROI from Day One

By implementing Tulip, manufacturers achieve:

• Higher product quality and fewer deviations
• Faster release cycles and improved traceability
• Increased productivity and reduced downtime
• Better cross-functional collaboration
• A scalable foundation for long-term digital transformation

Tulip transforms frontline work into a connected, data-driven ecosystem that delivers operational excellence.

Would you like to know more contact Richard Gould

Tulip

Real-Time Asset Tracking for Manufacturing

Gazpacho Tracking Real-Time Asset Tracking provides real-time visibility of assets across your production and logistics operations. Misplaced equipment, delayed materials, and inefficient workflows can slow production, increase costs, and frustrate customers. Gazpacho Tracking ensures operators always know where key assets are, reducing downtime, boosting efficiency, and improving overall operational performance.

By combining Real-Time Asset Tracking with ERP integration, you gain actionable insights that help you streamline processes, optimize material flow, and make informed decisions before small issues turn into major disruptions.

Production Challenges Solved by Gazpacho Tracking

Factories often face hidden operational hurdles:

• Delays in material flow and misplaced tools or components
• Inefficient internal logistics causing slower production cycles
• Limited visibility into assets and equipment utilization
• Safety risks from uncontrolled equipment or vehicle movements
• Errors caused by outdated floor plans or siloed information

Gazpacho Tracking solves these challenges by delivering continuous location data. Operators can quickly locate components, forklifts, or tools in real-time, simulate workflows, and avoid costly errors, improving efficiency and predictability across the facility.

Key Benefits Across the Organization

• Engineering & Planning: Faster project execution, better space utilization, fewer errors
• Production: Real-time KPIs, improved workflows, and digital work instructions
• Maintenance & Facility: Easy access to system and equipment information
• Health & Safety: Visualize risk areas and ensure compliance
• Operations & IT: Monitor assets, generate analytics, and support Lean initiatives

Gazpacho also allows Point of Interest (PoI) tagging, enabling operators to link equipment, work instructions, or safety information directly to assets for immediate context and guidance.

Choosing the Right RTLS Technology

The architecture of your asset tracking system is tailored to your specific needs and environment. Each technology, Wi-Fi, RFID, BLE, VSLAM, GPS, UWB, or LoRaWAN has strengths suited to different use cases.

We evaluate factors such as required accuracy, asset type, indoor vs. outdoor environment, battery life, and integration with existing systems to recommend the optimal solution. Whether you need continuous real-time tracking of materials, location-based alerts, or historical data for process improvement, we design a system that ensures reliable performance, scalability, and measurable impact on efficiency and productivity.

Case Study: Material Tracking at Sulzer Pumps

Background: Sulzer Pumps manufactures engineered-to-order pump packages for the energy industry. Handling numerous unique components across the shop floor posed operational challenges and long lead times. Sulzer needed a real-time solution to track components and equipment efficiently.

Approach & Solution: Virtual Manufacturing, developed Gazpacho Tracking using BLE hardware and advanced location algorithms. The system integrates ERP data with real-time location data, allowing operators to pinpoint items instantly (e.g., “Where is the shaft for Project Y?”).

Outcome & Advantage:

• Accurate real-time location of components and forklifts
• Reduced operational delays and material search time
• Expanded implementation to three additional factories
• Enabled digital Andon system for rapid operator support
• Foundation for analytics to generate spaghetti diagrams and improve material flow

Next Steps: Virtual Manufacturing is exploring advanced analytics and ERP integration to unlock even greater insights and continuous improvement.

Testimonial:
“We selected Virtual Manufacturing to deliver our material tracking solution due to their understanding of our needs and collaborative approach. From Day 1 after commissioning, we achieved our objectives and are now exploring additional areas to extract insights from the data.” – Andrew Anderson, Sulzer Pumps

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Why Choose Gazpacho Tracking?

With Gazpacho Tracking, manufacturing organizations can:

• Reduce downtime and production interruptions
• Optimize material flow and asset utilization
• Improve operator efficiency and workplace safety
• Support Lean initiatives with actionable, fact-based data
• Make data-driven decisions in real-time

From live monitoring to historical analytics, Gazpacho Tracking transforms asset visibility into operational performance and measurable ROI.

Would you like to know more contact Richard Gould

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Real-Time Energy Monitoring for Efficient Production that Optimize Your Energy Usage and Costs

In modern manufacturing, energy is not just a cost, it’s a strategic resource. Gazpacho Energy provides real-time energy monitoring, helping production teams identify hidden inefficiencies, reduce waste, and improve operational sustainability. By capturing precise energy data from machines, lines, and stations, you can see exactly when and where energy is consumed.

Solve Production Energy Challenges

Manufacturers face challenges like inconsistent energy consumption, high standby usage, and energy peaks during start-up. Gazpacho Energy makes these visible, allowing you to:

• Detect and reduce hidden energy waste
• Link energy usage directly to production activities
• Prevent costly inefficiencies without impacting output

From Insight to Action

With intuitive dashboards, Gazpacho Energy delivers updates every 30 seconds, showing consumption in amperes, kWh, and cost. You can take proactive action through automated alerts, email reports, or guided recommendations. This enables energy optimization, smarter production decisions, and measurable ROI.

Support for Sustainability and ISO 50001

Gazpacho Energy helps organizations meet sustainability targets and ISO 50001 requirements. By analyzing energy patterns, you can prioritize upgrades, plan investments, and set realistic Net Zero goals.

Who Benefits

• Engineering & Production: Optimize processes, reduce waste, and improve efficiency
• Management & Sustainability Teams: Track KPI progress, make informed investment decisions
• Maintenance: Identify underperforming equipment and schedule improvements

With Gazpacho Energy, data drives decisions. Reduce costs, improve sustainability, and make energy efficiency a competitive advantage.

Case Study: Data-Driven Energy Insights for Smarter Production

Wallåkra Mekaniska partnered with Virtual Manufacturing to uncover hidden energy patterns and turn real-time data into actionable insights. By installing Gazpacho Energy, they gained live dashboards, historical tracking, and machine-level analytics, enabling informed decisions that reduce costs, improve efficiency, and support sustainability.

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Would you like to know more contact Richard Gould