UDMTEK

Company

UDMTEK provides various application services by interpreting the execution of control logic and data flow characteristics with in automation systems through an explainable AI approach.

White Paper 2

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White Paper 2

Unlocking the Future of
Smart Factory Operations
with AI and Digital Twin Technology

Introduction

As manufacturing becomes increasingly automated and intelligent, the need for a comprehensive Factory Operating System (FOS) has emerged.

UDMTEK expands beyond machine-level control by offering an integrated platform that connects PLC/PC logic, IoT sensors, human operations, 3D digital models, and 4M resources (Man, Machine, Material, Method). This system supports engineering-to-IT synchronization, enabling real-time diagnostics and optimization through Edge Computing and AI.

Limitations of Fall Traditional Approaches

Traditional systems separate machine control from sensor data and operational activities. This siloed approach creates blind spots in process understanding and limits the ability to diagnose or prevent issues. AI models based only on external sensor data often miss root causes hidden in the control logic or manual operations. Without synchronization across levels, accurate process improvement is nearly impossible.

UDMTEK’s Smart Factory Operating System

UDMTEK’s FOS is a digital twin-based platform that synchronizes every aspect of the factory using edge-based architecture. The system includes

- Unified control logic interpretation (MLP): Control Language Translation & Interpretation Technology for different controllers
- Real-time IoT sensor integration
- Operator action tracking and analysis
- 3D model visualization and simulation
- Integration of all 4M elements into a traceable system

Every data point is timestamped and synchronized, enabling accurate root cause tracing and operational optimization.

Control Language Translation & Interpretation Technology for different controllers

Integrated Digital Twin for Distributed Automation Systems

System Architecture

The Factory Operating System connects multiple layers of data and processes through a unified platform. Below is an overview of its architecture

Factory Operating System Components

Component	Description
Control Layer	Interprets and synchronizes PLC/PC control logic using MLP.
Sensor Layer	Integrates IoT data (temperature, vibration, current, etc.).
Human Layer	Captures and analyzes operator input and manual controls.
3D Digital Twin	Connects real operations to a virtual model for simulation.
Material Layer	Tracks inventory and lot history linked to process data.
Method Layer	Monitors SOP compliance and process standardization.
Information Layer	Connects MES/ERP for full operational traceability.

Productivity and Quality Impact

UDMTEK’s FOS enables detailed analysis at every stage of production and control. Edge Computing allows immediate feedback and micro-level anomaly detection, enhancing both productivity and quality:

Benefit Area	Impact
Productivity	30–40% faster root cause analysis and downtime reduction.
Operator Efficiency	Improved SOP adherence and action traceability.
Quality	Micro-deviation detection before defects occur.
Traceability/td>	Full linkage from input material to final product.

Conclusion

UDMTEK’s Factory Operating System is not just a control platform

it is a comprehensive, intelligent infrastructure for next-generation manufacturing. By synchronizing and analyzing every operational detail through AI, Edge Computing, and digital twins, we provide factories the tools to self-diagnose, self-optimize, and continuously improve.