Accenture

Accenture Unveils Physical AI Orchestrator to Enable Software-Defined Manufacturing Facilities

October 28, 2025 - Accenture has introduced its latest innovation, Physical AI Orchestrator, a cloud-based solution aimed at transforming traditional manufacturing and warehouse operations into software-defined environments. The launch, made at NVIDIA GTC in Washington, D.C., integrates NVIDIA Omniverse technologies—including the “Mega” Omniverse Blueprint and NVIDIA Metropolis—with AI agents from Accenture’s proprietary AI Refinery platform.

Designed for high-tech, life sciences, and consumer goods sectors, the solution enables manufacturers to create live digital twins of their facilities. These twins, which mirror physical assets such as conveyors, industrial robots, and shop floor layouts, use real-time simulation and AI insights to optimize factory performance and responsiveness.

AI-Driven Simulation Meets Real-Time Adaptability

Software-defined facilities leverage virtual replicas to detect issues and simulate process changes using accurate physics modeling. AI agents interpret these simulations, generating precise instructions that allow physical operations to adapt to shifts in demand, quality requirements, or scheduling constraints.

Accenture's Physical AI Orchestrator empowers organizations to simulate both planned and existing assets, integrating them seamlessly with their physical counterparts.

Real-World Applications and Measurable Impact

At the launch event, Accenture highlighted early adopters already applying the technology:

Belden, a data and networking solutions provider, used the platform to develop a virtual safety fence. This system creates dynamic safety zones around robots and halts or redirects them if a human enters the zone—without halting overall operations. The solution, trained on complex scenarios like reversing forklifts, uses centimeter-level fidelity modeling and is set to be deployed by an automotive manufacturer to enhance pedestrian safety.

A life sciences company utilized Physical AI Orchestrator to simulate biologics and vaccine production conditions. By modeling temperature and pressure variations during preservation and drying processes, it identified deviation points, reduced batch variability, and extended product shelf life.

A consumer goods manufacturer improved warehouse efficiency by 20% and reduced capital expenditure by 15%. Through digital twin analysis of worker movements, picking rates, and conveyor operations, the company optimized layout and resource allocation without costly physical trials.

Core Capabilities of Physical AI Orchestrator

The platform offers a suite of features designed to make AI-native, software-defined manufacturing a reality:

Reality Capture: AI-driven tools convert scans and videos into high-fidelity 3D models, ensuring accurate and current digital twin representations.

AI Agents: Embedded intelligence supports engineers throughout the design and installation of new production lines by drawing on prior project knowledge.

Vision Analytics: Ingests real-time video data to enable precise simulations based on the movement of workers, vehicles, and materials.

Asset Connectors: Facilitates plug-and-play integration of existing equipment into simulations.

XR Extensions: Enhances training and collaboration through immersive, augmented environments linked to the digital twin.

Driving U.S. Manufacturing Reinvention

“Physical AI Orchestrator acts as a brain for a physical space,” said Prasad Satyavolu, Americas Lead of Accenture’s Digital Engineering and Manufacturing Service, Industry X. “Powered by NVIDIA Omniverse technologies and Accenture AI Refinery, it is designed to enable software-defined factories and to make agentic AI and physical AI part of the fabric of manufacturing. We are already seeing it provide quick and lasting benefits to our clients across the globe. This is particularly relevant to companies in the US, where manufacturing reinvention is a prerequisite for reindustrialization.”

The solution is expected to significantly reduce both product design costs and capital expenditures while enhancing the accuracy of factory planning and simulation. Early results suggest Physical AI Orchestrator is well-positioned to become a cornerstone technology in the next generation of intelligent, adaptive manufacturing systems.

Source: https://newsroom.accenture.com/news/2025/accenture-launches-physical-ai-orchestrator-to-help-manufacturers-build-software-defined-facilities

Accenture Acquires Systema to Boost Manufacturing Automation in Semiconductor Industry

July 2025 – Global consulting and technology giant Accenture has announced its acquisition of SYSTEMA, a leading provider of automation and digitalization solutions for manufacturing, to strengthen its capabilities in the semiconductor sector.

SYSTEMA, headquartered in Dresden, Germany, specializes in smart manufacturing systems and has a strong footprint in delivering software solutions that streamline production processes for semiconductor clients. The acquisition will enable Accenture to integrate SYSTEMA’s expertise with its Industry X services, helping clients accelerate their transition towards fully automated, intelligent manufacturing.

“With the semiconductor industry facing increasing complexity and demand for efficiency, this acquisition allows us to deliver advanced automation solutions at scale,” said Tracey Countryman, global lead for Industry X at Accenture.

The move reflects Accenture’s continued focus on expanding its footprint in Industry 4.0 and supporting semiconductor companies in adopting AI, IoT, and data-driven manufacturing technologies.

SYSTEMA’s team will join Accenture Industry X, bringing deep knowledge in manufacturing execution systems (MES), automation platforms, and end-to-end factory digitalization.

The terms of the deal were not disclosed.

This marks another strategic step for Accenture in building robust, future-ready supply chains and manufacturing systems for its global semiconductor clients.

Source: https://newsroom.accenture.com/news/2025/accenture-acquires-systema-to-drive-manufacturing-automation-for-semiconductor-clients