Overview

Providing manufacturers with intelligent analytics and contextualized data to enhance availability, efficiency, and quality.

Today’s manufacturers face a more complex production environment, where data comes from numerous disconnected systems spanning operations, equipment, and enterprise levels. Without an integrated strategy, valuable insights remain siloed, hindering timely, informed decision-making. bitsIO’s Industrial Data Intelligence Services offer a structured method to unify operational and business data, transforming fragmented signals into practical insights. By utilizing Splunk as the foundation for analytics and observability, bitsIO enables manufacturers to gain visibility across production lines, assets, and facilities—leading to quicker responses, better decisions, and measurable improvements in operational performance. Our services focus on aligning technology, data, and personnel around common goals: increasing availability, enhancing process efficiency, and improving product quality. The result is a modern manufacturing operation that predicts issues rather than reacts to them, powered by data that provides a clear, contextual story.

Approach

Structured methodology for connecting operational data to measurable outcomes.

bitsIO applies a practical and phased approach to industrial data transformation, designed to guide manufacturers through a maturity model that connects data collection, contextualization, and predictive insight. Our consultants work collaboratively with operations, engineering, and IT teams to ensure that transformation efforts yield measurable business results, rather than isolated technical projects.

Phase 1: Data Discovery and Alignment

In this phase, bitsIO performs a comprehensive data landscape assessment, identifying critical data sources, existing integrations, and visibility gaps. Our team evaluates the current use of manufacturing systems, historians, MES, PLCs, and sensors to determine the fastest path to operational insight.

Deliverables include:

• OT and IT data mapping and readiness assessment
  
• Data ingestion and normalization design using Splunk
  
• Alignment of KPIs to business goals (availability, efficiency, quality)
  

Phase 2: Contextualization and Visualization

Once data sources are connected, bitsIO develops contextualized visualizations that align production, maintenance, and quality data into unified views. Using Splunk dashboards and analytics models, manufacturers can correlate equipment status, operator activity, and process events to understand why performance changes occur.

Deliverables include:

- Splunk-based operational dashboards

- Context models linking process and production data

- OEE contextualization (availability, performance, quality)

- Plant and line-level health visualization

Phase 3: Operational Intelligence Enablement

The third phase focuses on operationalizing insights across teams. bitsIO trains plant personnel, engineers, and managers to conduct investigations directly within Splunk rather than relying on static reports. This phase emphasizes empowerment. Turning end users into active investigators who can identify issues, test hypotheses, and implement improvements quickly.

Deliverables include:

- Role-based training and enablement sessions

- Custom correlation searches and reusable templates

- Unified workflows for downtime analysis and anomaly detection

Phase 4: Predictive and AI Readiness

With contextual models in place, bitsIO prepares organizations to adopt predictive analytics and AI. We identify repeatable search patterns, correlations, and event models that form the foundation for machine learning. By structuring your Splunk environment around contextual logic, we establish readiness for predictive maintenance, process optimization, and AI-driven decision support.

Deliverables include:

- AI readiness assessment

- Predictive analytics design

- Automated alerting and recommendation workflows

Key Service Areas

Integrated consulting and enablement services for industrial transformation.

bitsIO’s Industrial Data Intelligence Services combine strategy, implementation, and enablement into a single engagement model. Each service area is designed to accelerate transformation, improve data quality, and maximize return on technology investments.

1. OT and IoT Data Integration – Comprehensive data connectivity across PLCs, HMIs, historians, and industrial gateways using Splunk’s edge-to-cloud data pipeline capabilities. bitsIO ensures that operational data is collected securely, efficiently, and in a manner that preserves contextual value.

2. Common Information Model (CIM) – Development of standardized data models that unify operational and business data within Splunk. Our consultants align models to ISA-95 and Unified Namespace principles, ensuring scalability and interoperability across plants and systems.

3. Operational Analytics Enablement – Deployment of Splunk dashboards, searches, and correlation logic tailored to plant operations. bitsIO provides hands-on enablement for SMEs, engineers, and managers to perform data investigations, identify root causes, and optimize production performance.

4. Predictive Analytics and AI Preparation – Configuration of advanced analytics models that enable forecasting and anomaly detection. bitsIO establishes the foundational search logic and data features that support future AI applications in quality control, maintenance, and throughput optimization.

5. Continuous Improvement and Governance – Ongoing support and governance frameworks that sustain analytics maturity. bitsIO provides continuous optimization services to refine dashboards, improve data accuracy, and align KPIs to evolving business goals.

Benefits and Outcomes

Quantifiable performance improvements and sustained operational excellence.

bitsIO’s Industrial Data Intelligence Services deliver measurable business results by connecting data-driven insight with operational performance. Each engagement is designed to generate improvements in three core areas that directly influence profitability: availability, efficiency, and quality.

Improved Availability

By unifying equipment and process data in Splunk, bitsIO enables proactive monitoring and rapid detection of anomalies. Maintenance and operations teams gain visibility into the conditions leading to downtime, allowing for faster corrective actions and better resource allocation.

Outcomes include:

- Reduction in unplanned downtime

- Improved maintenance scheduling accuracy

- Faster mean time to repair (MTTR)

Increased Efficiency

Real-time visibility into asset utilization and process flow allows for immediate identification of production bottlenecks and performance issues. bitsIO helps organizations correlate data across shifts, lines, and departments to optimize throughput and reduce waste.

Outcomes include:

- Increased equipment utilization rates

- Reduced process variability and idle time

- Enhanced production planning and scheduling

Enhanced Quality

Quality performance improves when data from equipment, operators, and process sensors is analyzed together. bitsIO enables cross-functional visibility into quality-related events, enabling teams to pinpoint the sources of deviation and establish preventive measures.

Outcomes include:

- Fewer quality defects

- Faster feedback loops for process adjustments

- Improved customer satisfaction and product reliability

Organizational Empowerment

Beyond technology, the most significant outcome of bitsIO’s services is a shift in organizational capability. Teams become more data-driven, investigations become faster, and decision-making becomes grounded in evidence rather than assumption.

Results

Proven framework for measurable improvement.

Organizations that engage with bitsIO experience tangible performance gains across availability, efficiency, and quality metrics. By combining Splunk’s analytics platform with bitsIO’s industrial expertise, clients achieve sustainable transformation that scales from individual plants to enterprise-wide operations.