AI for Manufacturing

Accelerate the journey towards AI-powered intelligent operations

Making sense of the wealth of data produced by a connected factory, and implementing truly closed loop and ultimately autonomous operations, is clearly beyond the reach of existing manufacturing systems and traditional Lean Manufacturing techniques. The Industry 4.0 ambition of self-optimizing manufacturing systems will then require the systematic application of AI technologies.

Despite conclusive pilots for such use cases as predictive maintenance or quality, most manufacturers are failing to reap the full benefits of their Smart Factory/Industry 4.0 programs.

Only 14% of the respondents to a recent study by Capgemini Research Institute have managed to scale beyond those initial pilots and systematically deploy across all their factories.

Leveraging its unique range of expertise, from Intelligent Control Systems and IoT architectures to AI-powered solutions, Capgemini is co-innovating with leading clients and partners to complement and extend existing manufacturing systems with an open and scalable Intelligent Operation Platform.

The Intelligent Operations Platform supports the transition of manufacturing from repeatable to transparent, optimized, and ultimately autonomous (self-optimizing) operations. Its open and extensible architecture allows to apply AI for gradual improvements of existing manufacturing operations without extensive “rip & replace” of existing systems, based on issue focused solutions that pay for themselves in a matter of months

To accelerate and de-risk Smart Factory/Industry 4.0 “at scale” roadmaps, our experts have developed accelerators for these issue-based solutions, from simple condition-based maintenance to advanced process optimization.

Our response? AI for Operations Intelligence, with a key component our AI-powered Intelligent Operations Platform (IOP). This combines a multi-cloud/hybrid/on-premise tech Platform, and pre-built AI manufacturing solutions or accelerators. We also provide advisory services to establish a digital manufacturing operating model. Reference architectures of the Platform are available for Microsoft Azure, AWS, and Google Cloud, with Capgemini’s modules based on open source technology.

This combination ensures agility to operations, resulting in reduced time-to-market, boosted productivity, and decreased unplanned downtime – all under the promise of safety and uncompromised quality.

Major AI-driven applications include:

  • Predictive Maintenance
  • Quality Inspection with Deep learning and Computer Vision
  • Worker Safety
  • Asset Performance Management
  • Supplier Performance Monitoring
  • Energy Savings
  • Adaptive Scheduling and
  • Digital Control Tower.

Our industry consultants work with clients to define their own roadmap, based on their initial situation and objectives, including the establishment of a sustainable digital manufacturing operating model.

The AI-powered Intelligent Operations Platform covers all the layers of the “stack”, from data acquisition to agile applications development. The Platform has reference architectures and can be implemented on all major clouds: Microsoft Azure, AWS, Google Cloud, or hybrid. Some of the Platform services are based on open source technologies to limit lock-in.

The platform provides integration to existing systems to support end-to-end process optimization as well as “digital continuity” along the lifecycle of products, assets and factories. Built with continuous evolution in mind, it will allow companies to leverage Industry 4.0 technologies, such as IoT & embedded sensors, AR/VR, Cloud, machine learning in the cloud and at the edge, and upcoming 5G connectivity, to constantly innovate the way they operate.

We support our clients at all stages of Industry 4.0 transformation:

  • Initial AI pilots like machine-learning based predictive maintenance or visual inspection for quality, delivered in a few weeks thanks to accelerators, to experiment and mobilize the organization with early successes,
  • Industry 4.0 Advisory – advisory service to guide your transformation towards a platform-based Industry 4.0 Operating Model – people/process/technology
  • Re-architecture of existing manufacturing systems, combining classical MES and AI-powered Intelligent Operations Platform, or improving Industrial Control Systems,
  • AI Use Cases Foundry to support deployment at scale of focused Intelligent Operations use cases, including development and transfer of supporting competencies.



Pascal Brosset, AI in Manufacturing Offer Lead

To optimize increasingly complex factories and supply chains, production managers need support beyond “smart dashboards”.

IDC FutureScape: Worldwide Manufacturing Predictions

By the end of 2020, one-third of all manufacturing supply chains will be using analytics-driven cognitive capabilities.

Capgemini Research: Smart Factories and the Modern Manufacturer

Though 76% of manufacturers either have a smart factory initiative that is ongoing or are working on formulating it, only 14% of companies are satisfied with their level of success.

Meet our Experts

Anne-Laure Thieullent

Vice President, Artificial Intelligence and Analytics Group Offer Leader