EXP Software GmbH
Use Case · Manufacturing

Product and factory as one shared Agentic Twin

In high-variant manufacturing, problems often surface only on the shop floor. explore validates every configuration up front on the digital twin, so you go into production faster, safer and without costly surprises.

Product and factory as one shared Agentic Twin
The Challenge

Problems often surface on the shop floor, not in planning

In high-variant manufacturing, it only becomes clear late whether an ordered configuration can actually be built on the real line. Errors surface on the shop floor, not at the desk.

The result is rework, downtime, costly change loops and a delayed production start, while engineering, planning and manufacturing work from separate data states.

Quality

Late error detection

Clashes and non-buildable variants only surface on the shop floor.

Cost

Expensive rework

Errors in production mean scrap, rework and unplanned change loops.

Time

Delayed production start

Every manual hand-off between engineering, planning and the line costs days.

Risk

Separate data states

Product, process and shop-floor data live in silos; nobody has the full picture.

The Solution

One shared Agentic Twin of product and factory

explore connects the product and the factory into one shared Agentic Twin. Engineering, configuration, manufacturing planning and the shop floor converge on a single, consistent data foundation, across all systems and across time.

Every variant is represented as it was ordered, or, if not yet ordered, fully simulated as it could be ordered. The result is an end-to-end Digital Thread from the configured product to the real line, on which Lora AI analyzes, evaluates and acts in coordination.

All of this information is available to AI through Lora AI, either directly in the system or via MCP, so agents and tools can access the Agentic Twin seamlessly.

Unlike classic, static digital twins, the Agentic Twin is built for agentic AI: it does not just represent, it evaluates, decides and acts, continuously updated from real shop-floor data.

Capabilities

What the Agentic Twin delivers in manufacturing

Buildability check

For every ordered or simulated variant, explore validates automatically whether it can be built on the existing line, before it enters production.

Lora Clash Analysis

Collisions between parts, fixtures and equipment are detected in the twin and evaluated in context, geometrically and along the entire process.

Assembly sequence

explore shows which parts are relevant at which station.

QM issues

Quality issues are pinned to the affected part and variant, with full traceability across product, process and time.

Decisions while the line runs

Fast, precise decisions while the line is running, based on the current state of product, line and order.

Catch problems early

The digital twin is validated before the BOM (bill of materials) goes into production. So problems are caught before they ever materialize on the shop floor.

Shop-floor connectivity

Shop-floor IoT events, processed in real time

The twin does not stay static: IoT events from the shop floor are processed continuously and mirrored back onto product and factory. So the Agentic Twin reflects the real state of production.

explore speaks OPC-UA as well as other modern IoT standards. Depending on topology, data is streamed via fog services close to the equipment or via cloud services through Kafka, scaling from a single cell to a plant network.

OPC-UAMQTTKafkaFog ServicesCloud Services
Shop-floor IoT events, processed in real time
The Result

Measurable impact in manufacturing

+5%
First-pass yield
higher first-pass yield because every variant is checked for buildability before production starts
−20%
Engineering change loops
because problems surface on the digital twin, not on the line
−30%
Time to variant release
through automated checks instead of manual coordination
< 4 h
Reaction time to shop-floor events
through real-time processing via OPC-UA and Kafka

Illustrative target values, to be validated per project.

Ready for manufacturing with explore?

See in detail how your product and your factory become one Agentic Twin.

Talk to an Expert
EXP Software GmbH

Our Agentic Twin Platform explore connects enterprise data across systems, time and partners to create a consistent view of reality, enabling teams to understand complex situations and turn insight into coordinated action.

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Contact
EXP Software GmbH
Ludwig-Hirschberger-Allee 11
85276 Pfaffenhofen, Germany
+49 8441 47247-0
kontakt@explore.de
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