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XcellAI|Industry 5.0 & Smart Manufacturing

Smarter plants, with people still in charge.

XcellHost connects your machines, edge and enterprise systems, then adds digital twins, predictive maintenance, vision inspection and cobots that take the strain off your operators. It follows the European Commission's Industry 5.0 idea: human-centric, sustainable and resilient.

IIoT sensors on old & new machines

Edge compute on the shop floor

MES, ERP & SAP integration

Predictive maintenance

Computer-vision quality checks

OT security aligned to IEC 62443

Operator in the loophuman-centric by design

Brownfield-friendlyOEM-agnostic retrofit

PLANT 1 · LINE 2Digital twin SHIFT A Sample

Machines running—of 6

Line OEE—A × P × Q

Good units—this shift

ANDON · LINE 2sample

Delivered byXcellHost Smart Manufacturing · MumbaiOEM-agnostic · IT/OT integration · 24×7 NOC + SOC

ISO 27001 & 20000-1Microsoft Gold Partner10,000+ customersSince 1999 · Mumbai99.95% uptime SLA*24×7 NOC + SOC

Overview · from Industry 4.0 to 5.0

Industry 4.0 connected the machines. Industry 5.0 asks what that does for people, the planet and the plant.

Industry 4.0 brought sensors, connectivity, data and automation to the shop floor. In January 2021 the European Commission set out Industry 5.0, which keeps that technology but changes the goal: industry should not chase efficiency alone. It should put workers' wellbeing and skills at the centre, use resources within planetary limits, and be able to absorb shocks such as supply disruptions. The Commission describes it as building on Industry 4.0, not replacing it.

For an Indian plant this is practical. XcellHost retrofits sensors on the machines you already run, processes data at the edge, links the shop floor to MES and ERP (including SAP), and then adds the use cases that pay back: a live digital twin, predictive maintenance, vision inspection, cobots that do the lifting while operators do the judging, and energy and carbon per unit. OT security is designed in from the start, and the platform is run by our 24×7 NOC and SOC from Mumbai.

Human-centric

Technology adapts to the operator, not the other way round: safer cobot cells, guided work, upskilling and decision support.

Operator decides, AI assists

Sustainable

Energy, scrap and emissions measured per unit, so you can cut them and report them with evidence.

kWh and CO₂e per unit

Resilient

Fewer surprise breakdowns, protected OT networks, and data that lets you re-plan fast when supply or demand shifts.

Predict, protect, recover

Source: European Commission, Directorate-General for Research and Innovation, What is Industry 5.0? and the policy brief “Industry 5.0: Towards a sustainable, human-centric and resilient European industry” (January 2021).

Capabilities · the smart manufacturing stack

Twelve building blocks. Start with one line, add the rest when it pays.

Each block works on its own and plugs into the others. Pick one to see what XcellHost delivers and where it links.

Architecture · how it works

Data climbs the levels. Decisions come back down to the line.

A reference design based on the Purdue model of industrial networks. Sensor data is cleaned at the edge, crosses a controlled IT/OT boundary, and feeds MES, ERP and AI. Models and work orders flow back down. Scroll to light it up, or tap a level.

Use cases · by sector

Same stack, different priorities. Pick your industry.

Typical first projects we scope for Indian plants. The KPI shows what to measure before and after, so the result is your number, not ours.

How XcellHost delivers

IT, OT and AI in one team. Run 24×7 after go-live.

XcellHost has run infrastructure for Indian businesses since 1999. We bring cloud, edge, networking, security and AI together, so your plant team deals with one partner instead of five.

Value first, one line at a time

We start with the line and the loss that costs you most, agree the KPI, and prove it before scaling.

OEM-agnostic, brownfield-friendly

Clamp-on sensors and protocol gateways for older machines; OPC UA, Modbus and MQTT where the controls support them.

Security before connectivity

OT zones, conduits and remote access are designed first, aligned to IEC 62443, with SOC monitoring.

Operators trained, not bypassed

Shop-floor screens, alerts and cobot cells are co-designed with the people who use them, plus AI training for staff.

INR quotes with GST

Fixed-price assessments, phase-wise project quotes and monthly run costs, all in INR with GST invoices.

24×7 NOC + SOC from Mumbai

Edge nodes, connectivity, platforms and OT alerts watched round the clock, with data kept in India.

Human-centric in practice

The cobot lifts. The operator decides.

Repetitive and heavy tasks move to the cobot · lifting, loading, screwing, palletising
Judgement stays with people · final inspection, exceptions, changeovers
Safety assessed per cell · risk assessment to ISO 10218 (2025 edition) with ISO/TS 15066 guidance for collaborative applications
Skills grow · operators learn to teach, monitor and improve the cell

India context & compliance

Built for Indian plants. Helps you meet the rules that apply.

Government programmes support manufacturing investment, and regulators increasingly ask for data on security, energy and emissions. XcellHost helps you produce and protect that data. It does not replace your own compliance or scheme applications.

Make in India

Launched on 25 September 2014 to grow manufacturing, investment and skills in India. Smart, competitive plants are its practical side.

PLI schemes

Production Linked Incentive schemes for 14 sectors, launched in 2020 with an outlay of ₹1.97 lakh crore. Incentives depend on verified production, so reliable output data matters.

SAMARTH Udyog Bharat 4.0

The Ministry of Heavy Industries' Industry 4.0 awareness initiative, with centres at IISc, CMTI, IIT Delhi (IITD-AIA Foundation) and the Kirloskar Centre for Learning in Industry 4.0.

MSMEs

Start small: one line, clamp-on sensors and monthly pricing. Check your Udyam registration and current MSME schemes for support you may qualify for.

SEBI BRSR

The top 1,000 listed companies file a Business Responsibility and Sustainability Report, mandatory since FY 2022-23, with energy and emissions data. BRSR Core assurance or assessment phases in by market cap through FY 2026-27.

CERT-In directions (2022)

Report cyber incidents within 6 hours and keep logs for 180 days in India. Our SOC and log design for OT and IT helps you meet both.

DPDP Act 2023

CCTV, biometrics and operator performance data are personal data. We design notice, purpose limits, access control and retention into shop-floor systems.

Private 5G (CNPN)

DoT's June 2022 guidelines let enterprises run captive non-public networks: lease spectrum from a telco, take it directly from DoT, or have a telco build or slice one.

Plans · assess, connect, then build

Fixed-price starts. Projects quoted to your line.

Indicative · excl. 18% GST. Prices marked * are placeholders — confirm with XcellHost. Run costs reuse XcellHost's published IoT Cloud and Edge Cloud rates.

Assess

Smart factory readiness assessment

₹99,999per plant · one-time*

Line walk and machine & data inventory
OEE and loss baseline on one line
IT/OT network and security snapshot
Prioritised use-case roadmap with payback

Measure

Energy & carbon baseline

₹74,999per plant · one-time*

Metering plan for lines and utilities
kWh per unit and peak-demand profile
Scope 1 & 2 data map for BRSR
Quick wins list with estimated savings

Secure first Protect

OT Site Assessment

₹2,49,999first site · ₹1,49,999 each extra

Passive OT asset discovery
IEC 62443-3-2 zones & conduits
Risks ranked by plant consequence
Full OT Assessment details →

Build & run

Pilots & projects

On quotedigital twin · PdM · vision · cobots · MES/ERP

IoT Cloud from ₹49/device/month
Edge nodes from ₹14,999/node/month
Pilot on one line with an agreed KPI
24×7 run by NOC + SOC

Tools · measure before you buy

Two calculators. Your numbers in, your baseline out.

The OEE calculator uses the standard formula. The predictive-maintenance estimator is illustrative and every rate is editable.

Tool 1

OEE calculator

OEE = Availability × Performance × Quality

Shift length · min Planned stops (breaks, meetings) · min Unplanned downtime & changeovers · min Ideal cycle time · seconds per unit Total units made Good units (first pass)

0%OEE

Availability0%run time ÷ planned time

Performance0%ideal cycle × total ÷ run time

Quality0%good ÷ total

Why predictive maintenance pays

Catch it at P, not at F.

Most failures give warning. Vibration and current signatures change weeks before a bearing gets hot or noisy. Sensors and models spot that early change, so maintenance is planned into a shift change instead of stopping the line. The curve is the classic reliability concept; how much warning you get depends on the failure mode.

Tool 2

Predictive-maintenance ROI estimator

Illustrative · your inputs, XcellHost's published run rates

Critical machines Sensors per machine Unplanned downtime · h / machine / year Cost of downtime · ₹ per hour* Maintenance spend · ₹ per year* Analytics & integration · ₹ per year*

Downtime reduction* 20%

Maintenance cost reduction* 5%

How it is calculated

Downtime cost now   = machines × hours × ₹/hour
Benefit / year      = downtime cost × reduction %
                    + maintenance spend × reduction %
Run cost / year     = max(100, machines × sensors) × ₹49 × 12   (IoT Cloud)
                    + ceil(machines ÷ 25) × ₹14,999 × 12        (Edge S)
                    + analytics & integration (your figure)
One-time            = ₹49,999 IoT setup + ₹99,999* readiness
Payback (months)    = one-time ÷ ((benefit − run cost) ÷ 12)

Downtime cost now₹0per year

Benefit₹0per year · illustrative

Run cost₹0per year

Payback—after one-time cost

Net benefit · year 1₹0after one-time and run costs

ROI · year 10%net ÷ year-1 cost

Illustrative only. * Your figures or placeholders. Real results depend on failure modes, data quality and how fast maintenance acts on alerts. Run rates: IoT Cloud ₹49/device/month (min 100), Edge S ₹14,999/node/month, excl. GST.

Compare

What changes from 4.0 to 5.0, and what XcellHost adds.

Typical Industry 4.0 projectIndustry 5.0 with XcellHost

GoalOutput and efficiencyOutput, plus worker wellbeing, energy and resilience

Operator's roleMonitored by the systemSupported by it: guided work, cobots for heavy tasks

KPIs trackedOEE and throughputOEE, plus kWh and CO₂e per unit, safety and skills

MaintenancePreventive, by calendarPredictive, by condition, with work orders in your CMMS

OT securityAdded after connectingDesigned first, aligned to IEC 62443, SOC-monitored

Where data livesOften a foreign SaaS regionOn-site edge and XcellHost India cloud

After go-liveSeparate vendors per toolOne partner, 24×7 NOC + SOC from Mumbai

Steps · how a programme runs

Six steps. Each one ends with a number you can check.

01Discover
Line walk, machine and data inventory, people and pain points.
Output · loss map
02Assess & secure
OEE baseline, OT security snapshot, network and edge design.
Output · roadmap
03Pilot one line
One use case, one KPI, measured before and after.
Output · proven KPI
04Scale
Roll out to more lines and plants; integrate MES and ERP.
Output · plant-wide data
05Operate 24×7
NOC + SOC monitor edge, platform and OT alerts.
Output · uptime & alerts
06Improve
Quarterly review of KPIs, models, energy and skills.
Output · next use case