Why Most DX Projects Fail — and How We Fix That
Digital transformation in manufacturing has a high failure rate — not because the technology doesn’t exist, but because projects are handed to IT departments or strategy consultants who don’t understand factory operations.
QAS is different. We live on the shop floor. We’ve commissioned PLCs at 3am, built MES that operators actually use, and integrated SAP with machines that were installed before SAP existed. Our transformation programmes are grounded in manufacturing reality.
The QAS Digital Transformation Framework
Five interconnected pillars that turn a fragmented factory into an intelligent, connected operation
Current-state audit, gap analysis, digital maturity scoring, business case development
IIoT device connectivity, protocol unification, edge computing, real-time data collection
MES, electronic work instructions, digital quality, paperless shop floor, SCADA/HMI modernisation
ERP integration, MES-SCADA-WMS-QMS connectivity, master data sync, end-to-end data flow
AI/ML analytics, predictive maintenance, OEE optimization, closed-loop quality, continuous improvement
Every Capability Under One Roof
No handoffs to other agencies. Strategy, engineering, integration and support — all in-house at QAS.
Digital Maturity Assessment
We score your factory across 6 dimensions of digital maturity, identify quick wins and long-term priorities, and produce a board-ready business case with ROI modelling.
Digital Transformation Roadmap
A prioritised, phased roadmap aligned to your budget, headcount and production calendar. Milestones, KPIs and governance model included — a live document we update throughout the programme.
MES & Paperless Shop Floor
Electronic work instructions, digital quality checks, real-time WIP tracking and shift reporting — built on QAS custom MES or third-party platforms (Siemens, SAP ME, Rockwell).
IIoT & Machine Connectivity
Connect every machine, sensor and robot to your data platform using OPC-UA, MQTT, Modbus and proprietary protocols. Edge computing for local processing, cloud for analytics.
ERP & Systems Integration
Bidirectional integration between SAP, Oracle, Dynamics and your shop-floor systems. Production orders, goods movements, quality results and cost data flow automatically.
AI Analytics & Predictive
OEE dashboards, predictive maintenance models, quality prediction, demand forecasting and anomaly detection. Built on your own data — no black-box vendor model.
SCADA & HMI Modernisation
Upgrade ageing HMI screens and SCADA servers to modern, web-based, mobile-accessible platforms — with alarm rationalisation, historian integration and remote access built in.
Change Management & Training
Technology is only half the transformation. We design operator training, supervisory workflows and maintenance procedures so the new system is adopted — not fought.
Long-Term Support & Evolution
Post go-live is not the end. We provide hypercare, quarterly system reviews, enhancement backlogs and proactive monitoring — your transformation partner for the long haul.
Before Digital Transformation vs. After
Sectors We Have Transformed
Automotive
Body shop, assembly, paint & chassis lines. SAP PP integration, quality gates, takt-time monitoring.
Pharmaceutical
FDA 21 CFR Part 11, batch record, serialisation, GMP-compliant MES and SCADA.
Tire Manufacturing
Cure monitoring, compound tracking, OEE per cure press, batch traceability to raw material.
Electronics & Semiconductor
SMT line monitoring, wafer tracking, yield analytics, cleanroom data collection.
Consumer Goods
Production scheduling, packaging line automation, inventory management, ERP sync.
Electric Vehicles
Battery assembly tracking, formation data capture, quality gates and full cell-to-pack genealogy.
A Typical Transformation Journey
Phased for minimum disruption — early phases pay for later ones
Technologies We Deploy
MES & Shop Floor
IIoT & Connectivity
Analytics & AI
Integration & ERP
Transformation Without the Consulting Overhead
We are a manufacturing automation company first. Every recommendation we make is tested against real factory constraints — shift patterns, safety requirements, production pressure and legacy equipment.
Where Is Your Factory on the Digital Journey?
Book a free 60-minute digital maturity workshop — we’ll score your factory, identify your biggest opportunities and sketch a realistic roadmap with ROI figures attached.