Smart Factory

A Smart Factory: a practical path for SMEs

by Seleena Creedonin Industry Newson Posted on

A Smart Factory: a practical path for SMEs

Digital manufacturing is no longer reserved for global giants with unlimited budgets. Across the UK, manufacturers of all sizes are adopting Smart Factory principles to improve productivity, quality, and resilience. The challenge for many SMEs is knowing where to start, how much to invest, and how to see results quickly.

At Devtank, we help manufacturers take a pragmatic, phased approach to becoming a Smart Factory using proven technologies for monitoring, production testing and connected data. Our HILTOP and OpenSmartMonitor products deliver measurable improvements without excessive upfront costs.

What is a Smart Factory?

A Smart Factory is a manufacturing environment where machines, systems and people are digitally connected, enabling real-time visibility, data-driven decision making and continuous improvement.

Smart Factory initiatives are often aligned with:

  • Industry 4.0 principles
  • The Made Smarter programme
  • SME-focused digital adoption strategies

Rather than full automation from day one, manufacturers and OEMs typically evolve towards smart manufacturing by:

  • Connecting existing machines and assets
  • Capturing live production and quality data
  • Using analytics to reduce downtime, waste and energy use
  • Automating individual labour-intensive tasks to improve productivity and quality

This incremental journey is especially important for SMEs, where investment capital is not always easy to find and return on investment must be clear and fast.

 

Real Smart Factory journeys: from SMEs to global manufacturers

There is no single route to becoming a Smart Factory, but successful journeys share common traits.
SMEs often begin with monitoring: understanding machine utilisation, downtime causes or energy consumption. From there, they often expand into predictive maintenance, quality tracking and digital work instructions.

Larger manufacturers, such as JCB, have demonstrated how digitalisation, connected factories and data-led improvement can deliver scale, efficiency and traceability across complex operations.

At Devtank, we work with both ends of this spectrum. The same principles that support enterprise manufacturers are applied in a more accessible, cost-effective way for SMEs.

 

Where HILTOP adds value in a Smart Factory

HILTOP is Devtank’s modular platform designed to support critical manufacturing functions as factories become smarter and more connected.

HILTOP can support:

  • Production testing and validation
    Automated and repeatable test processes with digital pass/fail results, full traceability and reporting of metrics. 
  • Quality assurance and compliance
    Capture inspection data, reduce manual paperwork and improve audit readiness. 
  • Predictive maintenance and asset health
    Monitor machine condition to identify issues before failures occur. 
  • OEE and downtime analysis
    Understand availability, performance and quality losses in real time. 
  • Digital workflows and operator guidance
    Reduce errors with structured processes and digital sign-offs.
  • Traceability and genealogy Track products, components and batches across the production lifecycle. 

HILTOP modules can be deployed individually or combined as part of a longer-term Smart Factory roadmap.

 

OpenSmartMonitor: the easiest first step to becoming smart

For many SMEs, the biggest barrier to Smart Factory adoption is visibility. This is where OpenSmartMonitor plays a crucial role.

OpenSmartMonitor provides a low-cost, fast-to-deploy monitoring layer that connects machines, sensors and systems to meaningful dashboards and alerts.

Key benefits include:

  • Rapid connection to existing machines and sensors 
  • Real-time dashboards for production, maintenance and management 
  • Automated alerts for downtime, performance or condition thresholds 
  • Pre-configured KPIs such as OEE, MTBF, scrap and energy usage 
  • Edge and cloud deployment options 
  • Open integration with ERP, MES and reporting tools 

By starting with monitoring, manufacturers gain immediate insight into where losses occur, often uncovering improvement opportunities that fund the next stage of digitalisation.

 

A Smart Factory roadmap for SMEs

Devtank typically supports SMEs through a phased approach:

1. Identify high-impact pain points

For example, frequent breakdowns, inconsistent quality, labour-intensive operations or energy costs.

2. Deploy monitoring with OpenSmartMonitor

Capture baseline data with minimal disruption.

3. Deliver quick wins

Reduce downtime, scrap or unplanned maintenance through actionable insights.

4. Expand using HILTOP solutions.

Introduce production testing, QA automation or predictive maintenance.

5. Integrate systems and scale

Connect data to business systems and extend across more lines or sites.

 

This approach minimises risk, controls costs and ensures every step delivers value.

 

Why monitoring is the foundation of a Smart Factory

Before automation, AI or advanced analytics, manufacturers need reliable data. Monitoring provides that foundation.

With OpenSmartMonitor and HILTOP, manufacturers can:

  • Make hidden losses visible
  • Prioritise improvement efforts
  • Justify future investment with real data
  • Build a scalable Smart Factory architecture over time

Smart manufacturing doesn’t have to be complex or expensive – it just needs to start in the right place.

Whether you’re an SME taking your first step or an established manufacturer looking to scale digital capability, Devtank can help you move forward with confidence.

Talk to us about monitoring, production testing and Smart Factory solutions that work in the real world.