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// Define · Measure · Analyse · Improve · Control

Industrial
Automation
For Your
Plant.

DeMAICo delivers smart industrial and automation solutions — Automated CI/CD pipelines for control systems, simulation APIs, MES automation, SAP integrations, automated batch records, and a continuous Six Sigma Lean Production analytics platform that turns historian and process data into measurable process improvement.

Our Services How We Work
8 Specialist solutions
4+ Industries served
0 Platform replacements required
How We Work

Our
Engagement
Model

Every engagement — whether CI/CD for control systems, SAP–MES integration, test automation, or Six Sigma analytics — runs the same DMAIC cycle. It is our delivery framework for all industrial engineering work: a structured method that scopes, builds, validates, and sustains every solution we deliver.

D
Define
Scope the full engagement. Map your OT and MES systems, integration points, and automation gaps. Define CTQs, compliance obligations, and deployment targets — establishing exactly what needs to be built before any solution is proposed.
M
Measure
Baseline current state across every dimension. Measure deployment frequency, change failure rate, integration reliability, and process sigma. Quantify the gap between where your automation and process performance are today and where they need to be.
A
Analyse
Design the full solution architecture — CI/CD pipeline topology, integration message flows, automation workflows, and analytics configuration. Tooling choices, compliance mapping, and a phased delivery plan with clear milestones and acceptance criteria.
I
Implement
Build and deliver. CI/CD pipelines for OT and MES, system integrations, automated testing suites, batch record automation, simulation APIs — built with your team and demonstrated at every milestone before moving forward.
C
Control
Handover, documentation, and team enablement. The DMAIC analytics platform takes over — continuously monitoring process health, detecting anomalies, and tracking improvement actions. Your team owns the solution, and the gains are locked in.
Who We Serve

Industries
We Work
In

DeMAICo brings industrial DevOps expertise to environments where software errors have real-world consequences. Our consultants understand both the code and the process it controls.

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01
Oil & Gas & Petrochemical
Pipeline control, refinery DCS, and offshore SCADA — where OSHA PSM and MOC are operational mandates, not checkboxes.
02
Chemical Manufacturing
Batch and continuous process control — IEC 62443-compliant pipelines with PSSR automation and full MoC audit trails.
03
Pharmaceutical & Biotech
GxP-aligned change control, 21 CFR Part 11–aware pipelines, and validated deployment workflows for regulated environments.
04
Discrete Manufacturing
Automotive, aerospace, and electronics — version-controlled PLC programs and MES DevOps for high-mix production environments.
05
Power & Utilities
Substation automation, SCADA modernization, and IEC 62443-compliant CI/CD for critical infrastructure.
06
Food & Beverage
Hygienic process control, recipe management pipelines, and OT version control for continuous and batch production lines.
Six Sigma Lean Production Analytics Platform

Continuous
Process
Intelligence

A purpose-built analytics engine that connects directly to your historian and MES — running the full DMAIC cycle continuously, not just at project milestones. CTQs are defined once; the platform measures, detects, classifies, and tracks improvement automatically, giving your team a live view of process health across every line and site.

01
Real-Time Measurement
Historian tags polled every 5 seconds against CTQ spec limits. Process capability (Cp, Cpk), OEE, and sigma level updated continuously — not in monthly reports.
02
Anomaly Detection
Rule-first ML engine: deterministic rules (priority ≥80) block ML inference. CUSUM, EWMA, and Western Electric SPC rules applied simultaneously to every tag.
03
Waste Classification
Every detected deviation is automatically classified against all 8 DOWNTIME waste categories — giving Lean teams an audit-ready evidence base without manual data gathering.
04
Improvement Tracking
Improvement actions logged with baseline and target sigma. Status advances open → in progress → verified → closed, with before/after sigma delta shown for every closed action.
05
GMP Audit Traceability
Every detection decision is source-attributed — rule name or ML model version, threshold, and timestamp. Compliant with 21 CFR Part 11 and EU GMP Annex 11 requirements.
06
Multi-Site Fleet View
Cross-project health dashboard surfaces the sites needing immediate attention — health score, critical anomaly count, SPC violations, and top waste category in a single triage view.
Smart Plant Automation Services
CI/CD for DCS / SCADA
Every PLC and DCS configuration change is version-controlled, peer-reviewed, and deployed through an automated pipeline. MOC and PSM compliance checks run on every commit — eliminating manual checklists, closing audit gaps, and making rollbacks a one-click operation.
Simulation API Wrapping
Your Aspen Plus and HYSYS models become live services — callable by dashboards, schedulers, or any plant system via a simple API. Run what-if scenarios programmatically, integrate with your DCS or historian, and eliminate the manual back-and-forth of spreadsheet-driven simulation work.
Real-Time Simulation Feeding
Live PI Historian data flows directly into your simulation models — automatically cleaned, mapped, and delivered. Your simulations run on current plant conditions instead of yesterday's exports, giving you a continuously updated digital twin without building a new platform from scratch.
MES DevOps
Configuration changes that once dragged through months of informal processes move through structured, version-controlled pipelines. Every change is reviewable, every deployment is repeatable, and rollbacks take minutes instead of days — dramatically compressing project timelines.
Automated Testing for MES
UAT cycles that consumed weeks of engineer time run overnight. Manual test scripts are replaced with automated test suites that execute consistently, catch regressions before they reach production, and produce documented evidence — turning the most painful part of every testing project into a non-event.
SAP–MES Integration Architecture
Production orders, material movements, and quality results flow reliably between SAP and your MES through a resilient message queue — not brittle point-to-point connections. One system going down no longer stalls the other, and the interfaces stop requiring constant engineer attention to stay operational.
Automated Batch Records
Batch records are compiled automatically at batch close — pulling from MES, PI Historian, and LIMS simultaneously — with deviations flagged in real time rather than discovered during QA review. What used to take days of manual data gathering is available the moment the batch ends, with a complete, audit-ready package. Built for pharmaceutical and regulated manufacturing environments.
Our Work

Each demo shows a real DeMAICo deliverable with simulated plant data. Connect your historian, MES, or simulator and the data becomes live.

MES DevOps
Config-as-Code CI/CD Pipeline
Recipes, lines & environments as YAML in Git. CI validates schemas & business rules, CD deploys via snapshot → dry-run → smoke-test with auto-rollback.
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CI/CD for DCS / SCADA
OT CI/CD Pipeline
8-stage CI pipeline for PLC/DCS/SCADA config changes. Compliance checks (IEC 62443, ISA-99, OSHA PSM) on every commit. MOC tracking.
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Real-Time Simulation Feeding
Historian Tag Pipeline
PI tags → validation → tag mapping → Aspen simulation. Live bad-value detection across 5 historian vendors, run history.
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Simulation API Wrapping
Aspen / HYSYS as REST
Job queue, worker status (Aspen Plus, HYSYS, UniSim), live POST→poll→result API log, hourly throughput.
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Automated Testing for MES
MES Automated Testing
6 vendors × 4 UAT scenarios run overnight. SQL / REST / OPC-UA / MQTT access types, regression gate, evidence pack per vendor.
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SAP–MES Integration
Resilient Message Queue Bridge
Production orders, confirmations & quality results flow between SAP S/4HANA & ECC and 6 MES vendors via RabbitMQ — no brittle point-to-point connections.
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Automated Batch Records
Batch Close Automation — Pipeline · Deviations · eBR
At batch close, MES steps, Historian process data, and LIMS results are pulled concurrently via RabbitMQ. Deviations are detected, classified by severity, and routed through an operator comment and supervisor sign-off workflow — all before a human touches the record. Outputs an audit-ready eBR (PostgreSQL + PDF) compliant with 21 CFR Part 11 and EU GMP Annex 11.
View Demo →
DMAIC Process Analytics
Continuous DMAIC Pipeline — Real-Time & Batch
Historian tags scored against CTQ spec limits every 5 seconds. Rule-first ML anomaly detection, CUSUM/EWMA/Western Electric SPC, 8-waste DOWNTIME classification, process capability (Cpk, OEE, sigma level), and improvement action tracking with before/after sigma verification.
View Demo →
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Ready to
Automate
Your Plant?

Tell us about your plant and its automation challenges. We'll schedule a no-obligation discovery call to walk you through which DeMAICo engineering solutions apply — and what results you can expect.

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