Digital Twin PlantOps

The Problem Automotive plants face three critical challenges: reactive maintenance causing costly downtime, energy waste invisible until monthly bills arrive, and siloed data preventing coordinated decision-making across operations, maintenance, and energy teams. Our Solution PlantOps Digital Twin Dashboard creates a real-time virtual replica of seven manufacturing zones (Stamping, Body Shop, Paint Shop, Assembly, Powertrain, Quality Control, Logistics), continuously monitoring energy consumption, equipment efficiency, temperature, and CO₂ emissions. When anomalies are detected-like a paint shop oven consuming 25% excess energy-IBM watsonx Orchestrate automatically orchestrates multi-step workflows: running predictive analytics, generating cost-impact reports, creating Jira maintenance tickets, and sending Slack alerts with corrective actions. Technical Innovation Our FastAPI backend exposes OpenAPI-compliant endpoints that watsonx Orchestrate imports as "skills"-callable tools for energy analysis, natural language queries, and maintenance scheduling. When a critical spike occurs, watsonx Orchestrate: (1) analyzes root causes, (2) predicts failure probability using ML models, (3) generates recommendations, (4) automates ticket creation, and (5) notifies teams-eliminating manual handoffs and reducing response time from hours to minutes. Business Impact $50K-$150K annual energy savings through real-time optimization 30-40% reduction in unplanned downtime via predictive maintenance 80% elimination of manual coordination tasks through workflow automation Tech Stack: React + IBM Carbon Design, Python FastAPI, scikit-learn ML models, Railway deployment The dashboard unifies plant-wide KPIs, zone-level diagnostics, and automated maintenance prioritization-all orchestrated through watsonx's intelligent workflow engine, demonstrating how existing APIs can be rapidly transformed into AI-powered operational excellence.