53% increase in overall production volume
39% reduction in field engineering operational costs
300+ device parameters governed effectively with AI solution
Owning Change in Manufacturing
Our customer is a global leader in water, hygiene, and infection prevention solutions, supporting over three million organisations across 170 countries worldwide. Driven by an unwavering commitment to sustainability and innovation, they deliver cutting-edge scientific solutions to enhance food safety, maintain clean and safe environments, and optimise water and energy utilisation at scale.
Overcoming Reactive, Field–Dependent Operating Models
Addressing Scalability Constraints in Distributed Site Engineering
One of our customer’s core business lines involves deploying specialised industrial devices to monitor pressure, voltage, frequency, and water and chemical consumption. Historically, deviations from target readings triggered on‑site diagnostic and reconfiguration activities by field engineers, driving high costs and constraining scalability across global sites. This reactive, site-dependent model limited our customer’s ability to respond to anomalies in real time across distributed environments.
To address this, our customer needed to increase production output while materially reducing overreliance on field support personnel. Achieving this required the introduction of an AI‑enabled solution capable of seamlessly and safely translating deviations across hundreds of device parameters into remote configuration actions.
AI–Enabled Remote Device Management Platform
Enabling Autonomous Device Optimisation Through Advanced Automation
Working in conjunction with our customer’s internal team, TEKsystems co-designed an AI-enabled, cloud-native remote configuration platform to automate device tuning and minimise manual, site-based intervention.
- Prompt–Driven Configuration Engine: Developed a microservice that converts structured prompts into controlled configuration commands for key device parameters such as frequency, water usage, and chemical ratios.
- Control Architecture: Leveraged Angular, Java, Spring Boot, and microservices to support monitoring, command execution, and exception handling.
- Firmware Automation: Enabled Programming Over The Air (POTA), allowing devices to retrieve firmware from the cloud and self‑reconfigure.
- AI Orchestration: Integrated Copilot, GitHub, and an internal firmware tool, using LangChain and LangGraph for sequencing and conditional logic.
- Parameter Governance: Governed 300+ device parameters using DynamoDB, with automated alerts triggering targeted field intervention only when required.
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Real-World Result
TEKsystems’ AI-enabled automation solution delivered measurable improvements in site engineering operational efficiency, cost optimisation, and scalability for our customer.
- Production Performance: Achieved a 53% year-on-year increase in production volume following AI platform deployment.
- Field Cost Reduction: Reduced field engineering visits and associated operational costs by 39% through remote configuration and automation.
- Device Optimisation: Delivered significant production and firmware cost efficiencies by simplifying device design and removing unnecessary circuits, PCBs, and capacitors.
- End-to-End Automation: Enabled remote configuration of critical parameters, including frequency, water consumption, and chemical usage, through a prompt-based interface.
- Global Scalability: Reduced dependency on local field presence across geographically dispersed sites, including regions without domestic coverage.
- Operational Resilience: Introduced automated exception detection with visual alerts and device location mapping to support targeted intervention.
- Workforce Efficiency: Reduced site maintenance requirements by 18%, enabling resources to be redeployed to higher-value activities.
