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How Industrial AI Takes Production to the Next Level

Industrial AI is the application of AI to real-world industrial operations, production systems and physical infrastructure in order to monitor, optimise and automate physical processes. It comes into its own where agents take on repetitive and complex tasks in production, whilst checking their own results before continuing. They utilise real-time data from sensors, robots and the Industrial IoT to improve decision-making during ongoing operations. This makes it possible to increase production figures and reduce costs and waste without the need for the number of skilled workers to grow at the same rate. Companies that rely on Industrial AI report immense potential, for example in predictive maintenance to prevent downtime, or in real-time quality control to minimise scrap immediately. This requires data generated by the plant that is available in a format which can be interpreted uniformly by all systems involved.

Challenges
in implementation

The most labour-intensive part of an industrial AI project is the brownfield retrofit. Before a model or agent can be deployed, companies must establish where the data from existing plant infrastructure comes from and in what form it is available.

  • Loss of control
    Autonomously operating AI agents are probabilistic systems. They make decisions and carry out actions independently. At the same time, hallucinations can occur, and compliance with regulations and quality standards is not automatically guaranteed.
  • Isolated brownfield sites
    Production data is generated by machines and control systems that were never designed to output it in a structured manner. Anyone who attempts to integrate them anyway ends up with individual point-to-point connections, which are expensive to develop and labour-intensive to operate. In brownfield environments, this effort increases with every additional interface.
  • Inconsistent data foundation
    Even when data flows, it is not yet usable. Each system produces its own formats, labels and time references. Without consistent semantics, it remains raw data that AI agents and analytics systems cannot work with.

Orchestra as a key to success for Industrial AI

Orchestra enables One-Click Industrial AI for legacy and brownfield systems. Existing systems can be connected in minutes without any modifications. The connection is secured using crypto-agile technology, and the data obtained is then made available in a format that allows analytics and AI agents to work with it immediately.

  • Retrofitting: secure and seamless
    Orchestra translates the relevant protocol directly at the plant without making any changes to the machine itself. Over 90 ready-to-use adapters cover the most common IT and OT protocols. No extensive programming knowledge is required, meaning even older systems can be connected. With Orchestra One-Click Industrial AI, this step is now even simpler: The software is installed directly on the machine, automatically recognises the machine and protocol, and sets up the connection independently. Every connection is encrypted using crypto-agile methods and is fully auditable, ensuring that communication between the plant and IT remains controllable at all times. Orchestra runs seamlessly and independently of the platform in the cloud, on-premises or in a hybrid environment. This allows companies to remain independent in their choice of systems.
  • AI-agent-enabled database
    Orchestra structures the connected data and standardises it semantically. Digital twins and a consistent namespace uniquely identify each asset and make data comparable across system boundaries. This creates the necessary foundation for true scalability: once the standard for a plant has been defined, AI logic can be efficiently rolled out across the entire factory and even across multiple sites. With a single click, IT and OT data becomes immediately usable for AI agents.
  • Secure governance for agents
    As a Secure AI Integration Layer, Orchestra integrates AI agents securely and in a controlled manner. Modular interface architectures, role-based access rights via RBAC and traceable audit trails keep technical and procedural risks manageable. This allows agents to operate in production without losing control over them.

Areas of application & use cases –
Where Orchestra makes the difference

Superior IT data interoperability for security and defence – commercial off‑the‑shelf

Secure trustworthy data

Bridging the IT/OT gap in greenfield and brownfield environments

Seamlessly connect the shopfloor

Digital integrity through compliance, auditability and traceability

Achieve maximum transparency

Orchestra enables legacy and brownfield systems to connect to AI agents

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Seamless, efficient and secure design of administrative processes

Connecting data securely

Efficiently implement manufacturer independence through a best‑of‑breed approach

Designing smart solutions

Reference architecture for the integration of OT and IT

Due to the increasing importance of holistic system considerations in manufacturing companies, the focus is shifting to IT architecture. There are currently a large number of different approaches, but no generally recognized reference architecture. In this white paper, we present a scientifically based elaboration of a reference architecture that you can use as a solution approach for the digital transformation in your company.

Break through traditional boundaries of your company and build the bridge between IT and your store floor.

Download reference architecture

Einblick in das Whitepaper Bridging the Gap zum Thema Referenzarchitektur zur umfassenden horizontalen und vertikalen Integration von OT und IT

Companies worldwide are relying on Orchestra

It is really impressive what soffico is getting off the ground: A topic as important for the digitalization of manufacturing as the Asset Administration Shell is discussed with top-class experts from research, industry and associations at soffico’s Industry Round Table

André Hoettgen

Industrie 4.0 Architect at Paul Horn GmbH

How you benefit

Industry 4.0 in your hands

 

Independent

Orchestra is not linked to specific manufacturers or technologies and acts in a platform-neutral manner.

Future-proof

Orchestra networks systems without changing individual working methods or technical environments. Upgrade old systems and standards through retrofit.

Agent-enabled legacy and brownfield systems

Orchestra uses MCP to provide data and processes from legacy and brownfield systems in a structured format for LLM-based AI agents. This enables context-sensitive workflow automation without the need to rebuild existing IT or OT architectures.

Scalable

Orchestra enables omnidirectional data flow. After simple and fast installation, it runs containerized on the edge up to a highly available cluster.

Low-Code

Scenarios can be implemented without programming experience.

Stable and reliable

Orchestra guarantees data completeness at all times through buffering and offline capability. Decentralized data (pre)processing increases efficiency and performance.

The perfect mix of software & service

A competent partner –
from the idea to the implementation

We develop efficient solutions for our international customers to optimize business, process and communication workflows. Through visionary thinking and modular concepts, future-proof, efficient and sustainable software solutions become a reality. Our goal is to ensure interoperability between the most diverse systems for a smooth and fast, but above all secure electronic data exchange.

About us

soffico GmbH develops software solutions for digital transformation. Our core is the software Orchestra, which is the backbone of digitalization for our customers and partners. We are an international team consisting of developers, consultants, creatives, support and partner management.

> 450 satisfied customers
> 2500 running installations

White papers and Best Practices

Benefit from our expertise

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Bridging the Connectivity Gap

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AI agents in established system landscapes

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White paper Digital Product Passport

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White paper Asset Administration Shell

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Die Produktion genau im Blick

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Good Manufacturing Practice with Orchestra

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IT/OT Konvergenz umgesetzt im Orchestra Designer mit Blick auf die Fertigung

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MES-Integration with Orchestra

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Fabrik im Daten Dschungel mit Fluss

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Let your Data flow

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Do you have questions?

We will be happy to help you with a personal consultation.

Talk to our Experts

Harald Wenger. Ihr Ansprechpartner für alle Themen rund um Orchestra.