The challenge
The organisation had valuable factory, telemetry, production, support, and energy data, but it was not consistently translated into operational action. Connectable products could reach customers without complete cloud registration records, creating avoidable connectivity failures. Engineering and support teams depended heavily on manual review to identify recurring failures, abnormalities, and quality issues. Energy reporting was useful but limited by telemetry gaps, approximate calculations, and a lack of clear customer-actionable guidance.
The approach
Defined a multi-workstream Azure AI and data programme covering manufacturing operations, predictive maintenance, quality optimisation, and smart energy recommendations. The manufacturing stream established factory-to-cloud ingestion, reconciliation data models, telemetry-assisted validation, exception workflows, operational dashboards, and API exposure. The predictive maintenance stream curated incident, telemetry, production, and support signals; captured engineering heuristics; and designed predictive models, quality dashboards, case enrichment, search, reporting, and workflow automation. The energy stream assessed energy telemetry, tariff and partner inputs, optimisation logic, recommendation services, customer insight APIs, and AI explanation patterns. The architecture used Azure-native services including Container Apps, Azure Data Explorer, Logic Apps, AI models, dashboards, APIs, and operational workflows.
The outcome
Created a structured delivery roadmap for turning connected product telemetry and operational data into measurable business value. The foundation enables earlier detection of factory-to-cloud provisioning gaps, automated exception handling, predictive failure and defect analytics, AI-generated quality reporting, energy usage recommendations, tariff-aware consumption insight, and customer-facing optimisation services. The approach provides a scalable Azure foundation for operational intelligence across manufacturing, quality, support, and energy management.
