IndusTANTRA Pvt. Ltd. — Industry 4.0 | Digital Twins

// 01 · PRODUCTS

Platform Modules

Click any platform to explore its capabilities in detail.

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Flagship · Integrated Platform

MaintelliGenX

Unified orchestration layer integrating all digital twin modules into one operations intelligence platform.

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✈

Turbofan · Gas Turbine · Physics-Informed · NASA C-MAPSS

AeroEngineTwinX

Four-stage physics pipeline — gas-path normalisation, signed deviation, component HI, RUL. Fan · LPC · HPC · Combustor · HPT resolved. 100% HI monotonicity. 709 engines. No run-to-failure labels.

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🛡

Full-Aircraft IVHM · 9 Subsystems · Physics ODE · Safety-Critical

AeroPHM-DT

Nine coupled subsystem digital twins — 62 state variables, 32 governing ODEs, 13 cross-subsystem couplings. Safety-weighted system Health Index. EASA · FAA · MIL-SPEC traceable.

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🚁

Helicopter · Drivetrain Health · STFT · ML Fault Classifier

CopterGBTwin

Helicopter engine and drivetrain health — MGB, IGB, TGB. STFT spectral physics + ML fault classifier names the component before it fails. 3.5-year fleet case study recorded to failure. Offline → Online.

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🚆

Wayside Intelligence · 21-Class Fault · CNN · EN Standards

RailTwinX

Physics-informed wayside platform — 16 sensor channels, 21-class fault taxonomy, 96.4% weighted F1. Train HI + Track HI from one wayside array. Grad-CAM explainability. EN 50126 · EN 50128 · EN 15313. Invited lecture, Railways 2026, Budapest.

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📡

Wayside · Plug-In Intelligence · Sensor-Agnostic · 25+ Sites

TrackPulse

Pre-trained Hyper-ML intelligence layer above any existing wayside system — WILD, DAS, fibre-optic, accelerometer. 12-class rolling stock fault taxonomy. Live Train Health Index per passage. No new hardware. 25+ sites. Day One deployment.

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⚙

Onboard · OEM · White-Label · Fleet-Agnostic · European Market

BogiePulse

Physics-informed onboard CBM engine for rolling stock OEMs. Fleet-agnostic, white-label ready. 28-channel hierarchical sensor fusion, dual-head CNN, Vehicle Health Index 0–100. New vehicle type in weeks. EN 50126 · ERA TAF TSI.

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⟳

Rotating Machinery · VibLab IITK · CNN · STFT

Rotor-Bearing-Gearbox Digital Twins

STFT spectrogram → VibLab IITK CNN v2 → 5-class fault diagnosis. Healthy · Unbalance · Crack · BPFO · BPFI. 93–100% accuracy. t-SNE visualisation. Health Index trending. Automated DOCX/PDF report.

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⚡

Power Generation · Condition Monitoring · FFT · Health Index

PowerPlantTwin

FFT condition monitoring for turbines and generators — 1× · 2× harmonic tracking, BPFO · BPFI · BSF bearing diagnostics, Health Index trending. LabVIEW → Python migration. DST-validated: NTPC · BHEL · CSIO.

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◈

Shopfloor DAQ · Live Dashboard · RFID · MCF Raebareli

Real-Time Production Monitoring

Live shopfloor intelligence — CNC, robot, and manual machine DAQ homogenised into one dashboard. RFID WIP tracking, Android HMI geo-location, cloud VPS relay. Deployed at MCF Raebareli under TMIR.

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▦

Shopfloor Digital Twin · SimPy Discrete-Event · MCF Raebareli

Process Scheduling

Full shopfloor discrete-event simulation at 1-minute resolution — priority dispatching, Gantt charts, bottleneck identification. 10-day lead time reduction at MCF Raebareli. 86–88% constraint utilisation quantified.

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Urban Digital Twin · Traffic · Event Management · IoT-Ready

Smart City Digital Twin

City-scale digital twin for large-footfall event management — OSMnx road network, zone congestion multipliers, animated green-to-red visualisation. IoT/ANPR/GPS integration pathway. Streamlit dashboard.

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SCADA · Power Infrastructure · Non-Intrusive ML

Hyper-ML for SCADA

Non-intrusive ML overlay on existing SCADA and DCS systems — OPC UA · IEC 61850 · Modbus. Anomaly detection, RUL prediction, digital twin bridging. No control-plane modification.

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✚

Social Impact · Health Camp Analytics · Doctors Consortium

Community Health Analytics Platform

Digital twin of population health — 18+ biomarker risk scores, individual patient PDF reports, locality-level risk stratification. Doctors consortium collaboration. Same twinning philosophy as industrial platforms.

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Social Impact · Clinical AI · Decision Support

Dr_AIde

AI-powered clinical decision support — symptom analysis, differential diagnosis, and triage intelligence for physicians and community health workers in resource-limited settings.

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👁

OT · IT Integration

OT–IT Bridge

Indigenous platform bridging shopfloor controllers with enterprise analytics — Modbus, OPC-UA, MQTT, RFID.

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// TECHNOLOGY DOMAINS

Component & System Dynamics Manufacturing Process Optimisation Sensors & Instrumentation Imaging & Quality Assurance Machine Learning · Deep Learning Health Diagnosis & Prognosis Rail–Wheel Contact Dynamics Nonlinear Parameter Estimation Smart City Systems Community Health Analytics

// 02 · PROJECTS

Major Projects

Flagship implementations and sponsored research across Indian industry and government.

Industry 4.0 · Railways

Technology Mission for Indian Railways (TMIR) — MCF Raebareli

Pilot-scale implementation of an integrated Industry 4.0 platform at Modern Coach Factory (MCF), Raebareli — India's most modern coach manufacturing facility. Three interconnected pillars: shopfloor monitoring, production scheduling, and RFID-based material tracking. Priority-based scheduling reduced completion time for highest-priority coach variants by up to 10 days vs random dispatching. Bottleneck analysis identified key stations at ~86–88% utilisation.

Digital Twin · Railways

Railway Digital Twin — Waltair Division, East Coast Railway

Design and implementation of a five-layer open-source digital twinning framework for Indian Railways, developed in collaboration with CRIS (Centre for Railway Information Systems). The Waltair (WAT) Division — serving Visakhapatnam Port, RINL steel, and petroleum freight — was selected as pilot. Framework spans data acquisition, model layer, analytics, and a cloud dashboard for remote monitoring. Presented at RAIL 26, Budapest.

Railways · Instrumentation

Wheel Impact Load Detection System (WILD)

Design and development of instrumentation system for wheel-flat detection — RDSO, 2001. Pioneering on-track load measurement system for Indian Railways.

Details →

Automotive · Electronics

Electronic Stability Program for Automobiles

Consortium project with IIT Bombay, TATA Motors, M&M, Ashok Leyland, TCS, Pricol — development of ABS, TCS and ESC for automobiles. Supported by CAR–TIFAC, DST.

Space · MEMS

IITK NanoSatellite — JUGNU

Design, development and launch of a MEMS-based micro-satellite. Project Coordinator under ISRO support. Successfully launched 2011.

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Power · DST

Condition Monitoring of Power Generation Machinery

Instrumentation systems for health monitoring of critical rotating machines for electric power generation. Joint project with CSIO Chandigarh, BHEL and NTPC. DST funded, 1996–2001.

Aerospace · ARDB

Turbine Blade Life Estimation Software

Software development for life estimation of turbine blades, and development of new techniques for determination of damping in rotors. Aeronautical Research & Development Board, MoD, 1992–2000.

Smart Systems

B-SMART / NPMASS

Board for Smart Materials Research and Technology; National Programme on Micro and Smart Systems. National coordinator and project leader.

// 04 · ABOUT

Founder & Director

vyas@iitk.ac.in

+91 9956292801

NL-103, MED, IIT Kanpur — 208016

Institutional Page →

Prof. Nalinaksh S. Vyas

Professor Emeritus, Department of Mechanical Engineering, IIT Kanpur
Former Chairman, Technology Mission for Indian Railways (TMIR), Govt. of India

Prof. Vyas holds a Ph.D. (1986), M.Tech. (1983) and B.Tech. (1980) — all in Mechanical Engineering — from IIT Delhi and IIT Bombay, and has been a faculty member at IIT Kanpur since 1987. His research spans Machine Dynamics, Nonlinear Parameter Estimation, Instrumentation, and AI/ML applications for Smart Infrastructure and Industry 4.0.

As Chairman of TMIR (till April 2022), he spearheaded the digital modernisation of one of the world's largest railway networks, including Industry 4.0 protocols at MCF Raebareli, on-board diagnostics for rolling stock, and deep learning for rail asset management.

He has held leadership roles including Head of Mechanical Engineering, Nuclear Engineering, and Centre for Mechatronics at IIT Kanpur; Vice Chancellor of Rajasthan Technical University (2013–15); and Visiting Professor at Virginia Tech, INSA Lyon, Lulea University, and National Chung Cheng University. He is a Founding Director of the International Society on Asset Management, Australia.

Incubated at IIT Kanpur under the Faculty Entrepreneurship Program (FEP)

MODULAR. SCALABLE.

Platform Modules

MaintelliGenX

AeroEngineTwinX

AeroPHM-DT

CopterGBTwin

RailTwinX

TrackPulse

BogiePulse

Rotor-Bearing-Gearbox Digital Twins

PowerPlantTwin

Real-Time Production Monitoring

Process Scheduling

Smart City Digital Twin

Hyper-ML for SCADA

Community Health Analytics Platform

Dr_AIde

OT–IT Bridge

Major Projects

Technology Mission for Indian Railways (TMIR) — MCF Raebareli

Railway Digital Twin — Waltair Division, East Coast Railway

Wheel Impact Load Detection System (WILD)

Electronic Stability Program for Automobiles

IITK NanoSatellite — JUGNU

Condition Monitoring of Power Generation Machinery

Turbine Blade Life Estimation Software

B-SMART / NPMASS

Founder & Director

Prof. Nalinaksh S. Vyas

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