Industrial Analytics & Machine Learning Platform
Industrial Connectivity & Edge for connected operations.
Connect equipment, systems, and real-time operations as the foundation of TCAIGV Industrial Intelligence Platform.
IoTAutoGen turns disconnected equipment, production signals, and business systems into one operational picture. See what is changing on the shop floor, identify emerging downtime and quality risks earlier, and give the right teams the context to act before a small issue grows.
Keep the systems that work today. IoTAutoGen can connect directly to legacy equipment, enhance MES, SCADA, historian, ERP, and CMMS environments, or combine both approaches. Protocols and edge connectivity become the proof behind a simpler outcome: faster root-cause analysis and better coordinated operations.
Start where you are. Build toward connected operations.
Deploy directly, alongside existing systems, or both. Every approach preserves the path to one operational view.
Get operational visibility without waiting for a full systems rollout.
Connect directly to equipment and establish the operational layer for lot and run context, alarms, traceability, maintenance, and live dashboards. Designed for greenfield factories and lines without a MES.
- Lot and run tracking
- Recipe and equipment state
- Alarm and traceability
- Maintenance tickets
- Live dashboards
Improve decisions without replacing the systems your teams rely on.
Connect existing MES, SCADA, historian, ERP, and CMMS data into one model, then add analytics, predictive maintenance, and action workflows across the stack you already own.
- Connects to existing MES / SCADA / historian
- Unified semiconductor data model
- Predictive analytics layer
- Action and workflow engine
- No system replacement
Connect each machine the right way, then operate from one view.
Bring legacy equipment in through the edge gateway while modern tools continue through MES or SCADA. Both streams become one consistent operational picture as you expand at your own pace.
- Direct gateway for legacy equipment
- Existing MES/SCADA for modern tools
- One unified data model for all
- Start small, expand per machine
- No forced full replacement
From production signals to better operations.
Explore the technical capabilities behind visibility, resilience, quality, maintenance, and connected decision-making.
Industrial Connectivity
Connect any device through OPC UA, SECS/GEM, Modbus, Profinet, MQTT, and legacy protocols. Unified device management across old and new equipment.
MES, SCADA, and Historian Integration
In Overlay or Hybrid mode, IoTAutoGen connects existing MES, SCADA, historian, ERP, and CMMS systems through an integration hub. Data normalizes into a unified model without replacing what you already have.
Asset and Remote Configuration Management
Track every asset from installation through its full lifecycle. Push configuration changes, firmware parameters, and setpoints to equipment remotely through a governed interface. Every change is versioned, audited, and reversible.
Operational Intelligence
Real-time KPI dashboards built from your actual equipment data. Monitor performance, set targets, and get alerts the moment a metric moves out of range.
Predictive Maintenance
AI learns the normal pattern for each asset and flags deviation early. Get maintenance recommendations before a fault occurs, not after.
Enterprise Systems and Supply Chain
Connect shop floor data to SAP, Oracle, and ERP in real time. Sync work orders, POs, parts inventory, and production schedules so operations, purchasing, maintenance, and finance all work from the same live data. No manual entry, no lag.
Unified Namespace and Multi-Vendor Data
IoTAutoGen normalizes data from every vendor and protocol into a single Unified Namespace. OPC UA, SECS/GEM, Modbus, and legacy systems all publish to the same semantic model. No custom mapping per vendor, no data silos between equipment types.
Command, Control, and Live Digital Twin
IoTAutoGen can serve as your central command-and-control center. Operators issue governed commands to any connected equipment from one interface. A live Digital Twin mirrors the real state of every asset in real time, so you see what the machine is doing before you act on it.
Multi-Plant and Global Operations
Connect plants across different sites and geographies into one central system. Each plant runs its own edge agents independently. A central IoTAutoGen instance aggregates data, enforces policies, and gives operations leadership a single view across every location worldwide.
Unified Edge Connectivity
Integrate edge devices and gateways into a hybrid edge-to-cloud pipeline. Real-time telemetry flows with low latency whether your setup is air-gapped or cloud-connected.
Native Protocol Gateway, Resilient Buffering, and AI at the Edge
IoTAutoGen ships with a native protocol gateway built into the platform, not a separate product. The gateway runs on your edge hardware, translates field protocols in real time, and buffers data locally when the network is unavailable. On reconnect, all buffered data is forwarded in order with no gaps. Remote management, HA deployment, and end-to-end encryption are included. Data is transmitted to any cloud or on-prem target using AMQP, MQTT, or HTTPS.
Native Protocol Gateway
The gateway engine is built into IoTAutoGen, not a separate product. It translates OPC UA, SECS/GEM, Modbus, Profinet, MQTT, and serial protocols into a unified data model in a single process, with no middleware required.
Resilient Buffering and Store-and-Forward
When the network goes down, the edge agent buffers data locally and preserves message order. On reconnect, all buffered data is forwarded to the target system without gaps. Configurable buffer size and retention policy per deployment.
AI at the Edge
Anomaly detection, predictive maintenance models, and equipment health scoring run locally on the edge device. No data needs to leave the shop floor for real-time AI inference.
Edge Capabilities
Supported Field Protocols
Validate in Simulation Before It Touches Production
You cannot run dev, test, or staging directly on a fab floor. IoTAutoGen ships with a full production-grade simulator - complete SECS/GEM state machine, live recipe execution, alarm generation, and ML model validation - so your team can develop, test, and certify integrations without touching a real tool.
Full Production Simulation
Every SECS/GEM message type, state transition, alarm, event, and recipe step runs in the simulator exactly as it would on real equipment. Develop and validate host software, MES hooks, and AI agents without access to the fab floor.
Fault Injection Testing
Seven built-in failure modes - temperature low, gas flow failure, door open, and more - let you test alarm handling, failover logic, and recovery procedures before your integration ever touches a real tool.
ML Model Validation
Train anomaly detection and predictive maintenance models on simulated telemetry streams. Validate accuracy, thresholds, and alert routing in a controlled environment before promoting to production equipment.
20 Pre-built Industry Scenarios
12 Simulated Device Types \u00b7 44 Built-in Recipes
MES Workflows, Live Operations, and Traceability Built In
When you run without a MES or SCADA, IoTAutoGen provides these manufacturing operations capabilities natively. When you have existing systems, it connects to them and adds what they cannot do.
Production and MES Workflow
Live Operations and SCADA-Lite Dashboard
Maintenance Intelligence
A dedicated maintenance module that turns your equipment history into actionable predictions. Track failures, manage logbooks, surface AI insights, and keep all your manuals and SOPs in one place.
Failure Tracking
Every fault, error code, and alarm is logged automatically with timestamp, equipment ID, and process step. Track MTBF, recurrence rates, and failure patterns over time.
Maintenance Logbook
Structured digital logbook per equipment - work orders, technician notes, parts replaced, and sign-off timestamps. Audit-ready records with full change history.
AI Maintenance Insights
Surface patterns across months of maintenance history. AI recommends the optimal maintenance window around your production schedule to avoid both failures and unnecessary downtime.
Predictive Alerts
Real-time anomaly detection on vibration, temperature, and pressure. Early warning thresholds built from each asset's own historical baseline, routed to the right technician automatically.
Document Library
Attach OEM manuals, SOPs, wiring diagrams, and safety procedures to each equipment profile. Auto-surfaced during a maintenance event with full version tracking.
Maintenance History and Reporting
Full timeline per asset from installation to present. Export compliance and audit reports. Cross-site maintenance analytics so you can compare performance across plants.
How AI Learns from Your Maintenance History
The AI does not use generic models. It builds a unique profile for each asset in your facility from real operational data.
Collects
Every fault, alarm, sensor event, and maintenance action is logged automatically from connected equipment. No manual entry required.
Learns
AI builds a unique performance baseline for each asset using its actual operating history. The longer it runs, the more accurate the model gets.
Predicts
The system flags upcoming risks and recommends specific actions before a failure occurs. Technicians get the right information at the right time.
Built Around the Operator, Not Just the Machine
Industry 5.0 puts humans back at the centre of industrial automation. IoTAutoGen is designed to augment operators, not replace them. AI handles data and detection. Humans make the decisions.
Human-AI Collaboration
Operators stay in full control. AI surfaces data, recommendations, and anomaly alerts but every action on equipment is confirmed by a human. The system works around the operator, not the other way around.
Worker Safety and Wellbeing
Workload monitoring, ergonomic alerts, and safe task routing ensure operators are not overloaded. Fatigue-aware scheduling and hazard proximity alerts keep your workforce protected.
Sustainable Operations
Energy consumption tracking per machine and process step. Waste reduction targets set against real production data. Efficiency gains that meet both your operational and sustainability goals.
Industry 5.0 Ready for Semiconductor Fab and Advanced Manufacturing
IoTAutoGen deploys across any advanced manufacturing environment. SECS/GEM (E5/E37/E30/E87/E90) for semiconductor fab tool-level control, OPC UA for plant-wide interoperability, and Modbus, Profinet, and MQTT for traditional industry protocols - all in one platform. Connect mixed-vendor environments, legacy tools, and modern equipment without a custom integration per vendor. Every signal feeds a full action loop: from equipment event to contextualised insight to human-approved action to verified business impact.
OPC UA Integration
- Secure sessions and namespace browsing for any OPC UA server
- High-frequency subscriptions for telemetry at millisecond resolution
- Command and write operations for setpoints, modes, and parameters
- Automatic reconnect and session recovery for continuous operation
SECS/GEM Support
- E5/E37 message handling (SxFy) for any SEMI-compliant tool
- Full GEM state model including remote commands and equipment constants
- Alarms and events collection with structured event forwarding to MES
- Recipe management and host command execution (E30 compliance)
Unified Orchestration
- Blend OPC UA and SECS/GEM data in one workflow without custom adapters
- AI chat and voice to query equipment status and trigger controlled actions
- Event-driven hooks to MES, ERP, and analytics systems in real time
- Support for custom tool vendor drivers and protocol adapters
Beyond Connectivity: Full Manufacturing Operations
IoTAutoGen is not just an equipment connectivity layer. It connects the shop floor to your enterprise systems so work orders, purchasing, parts, scheduling, and supply chain all respond to what is actually happening on the machines in real time.
Work Order Management
Equipment events and alarms automatically generate work orders. Technicians see the equipment history, relevant SOPs, spare parts needed, and sign-off workflow in one place. Every action is timestamped and traceable.
Purchase Orders and Procurement
When parts stock drops below threshold or a maintenance event consumes a component, the system can raise a draft PO, route it for approval, and sync it to SAP MM or your ERP purchasing module.
Spare Parts and Inventory
Track every spare part by equipment, BOM level, and location. Know what is in stock, what is on order, and what each machine is likely to need next based on its maintenance history and failure patterns.
Production Scheduling
Live equipment availability feeds directly into production schedule planning. When a machine goes into maintenance or a fault is detected, schedules adjust automatically and downstream teams get notified.
Supply Chain Visibility
Match incoming materials against production output in real time. Track supplier lead times against actual consumption. Flag gaps before they become delays on the floor.
SAP, Oracle, and ERP Integration
Native connectors for SAP PP, MM, PM, QM, and EWM. Oracle Manufacturing, Microsoft Dynamics 365, and custom ERP via REST or OData. Bidirectional sync with no middleware layer between equipment data and your ERP records.
Built to work with the standards your plant already uses.
IoTAutoGen speaks the protocols and standards found in factories and fabs, so it can sit alongside the systems you run today instead of replacing them.
SECS/GEM and SEMI standards
Message handling, the GEM state model, recipes, alarms, events, and host commands for fab equipment. Includes the carrier and substrate tracking standards used in fabs.
OPC UA
Open, vendor-neutral communication between equipment, gateways, and the systems that use the data.
Common field and messaging protocols
Connects PLCs, sensors, and cloud messaging using protocols found on most plant floors.
MES and ERP: built in or connected
Run the built-in MES, or connect the MES and ERP layers you already have. Plant-to-business data flow follows the ISA-95 model.
CMMS: built in or connected
Use the full CMMS module for work orders, assets, and maintenance history, or connect the CMMS you already run.
AGV support
AGVs move material on the factory floor and work with the MES and WIP tracking. Connect the AGVs you already have, or deploy AGV support as part of your plant operations.
From Equipment Signal to Business Impact
Most platforms stop at data and dashboards. IoTAutoGen closes the loop from equipment signal to corrective action, to verification, to business impact scoring. Every step is connected, tracked, and fed back into the model.
Observe
Equipment signal captured at the edge via OPC UA, SECS/GEM, or Modbus and normalised into the unified data model.
Understand
Signal is placed in MES context: which lot, which run, which recipe, which operator, which alarm history.
Predict
Analytics and ML models score equipment health, detect anomalies, and flag risk before a failure or abort occurs.
Act
An action card surfaces to the right person with evidence, business impact, similar past incidents, and a recommended next step.
Assign
The technician or engineer accepts, assigns, or escalates. A maintenance ticket is created automatically with full context attached.
Verify
After corrective action, the system checks if the signal pattern has resolved. Verification closes the loop and feeds the model.
Impact
Business impact is recorded: lots saved, hours of capacity recovered, cost of downtime avoided. Reported at plant and executive level.
One Platform for Every Plant, Anywhere in the World
IoTAutoGen supports a hub-and-spoke model where each plant runs its own edge agents and a central instance connects all sites into one view. Plants in different countries, time zones, and regulatory regions all feed into the same operational picture without losing local independence.
Why Choose IoTAutoGen?
One TCAIGV foundation for every layer of industrial connectivity, from device protocols to AI analytics, maintenance intelligence, and compliance-ready deployment.
Talk to UsOne platform for all your devices
Industrial, consumer, and legacy IoT devices managed from one interface. No more juggling separate tools for different equipment types.
AI that understands your environment
It reads your data, learns what is normal for each asset, and suggests or runs the right action for your specific setup.
Works with your existing systems
A protocol gateway keeps two-way communication open with SCADA systems and PLCs. APIs and webhooks connect to CRM, ERP, or other tools without custom integration work.
Control from anywhere
Plain language or voice commands. Central dashboard from web, mobile, Teams, or Outlook. 24/7 visibility across all sites and plants.
Built for regulated environments
Choose on-premises, air-gapped, or cloud deployment to meet your compliance and data sovereignty requirements.
Deployment & Integration Services
Beyond the platform, our engineers help you connect equipment, configure gateways, integrate data flows, and support your deployment.
Explore Industrial Connectivity ServicesReady to reduce downtime and connect your equipment?
Book a walkthrough and we will show it working with your protocols, device types, and maintenance setup.