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Industry: Manufacturing

Software development for manufacturing

Shop floor software that plant managers actually trust. We connect PLCs, historians and ERP into one data layer, build MES and quality apps around how your lines really run, and add AI for maintenance and inspection only where the data supports it. Senior engineers own the architecture, AI coding agents carry the volume, and every line is reviewed by a human.

Key highlights

  • We build MES modules, OEE dashboards, quality traceability and maintenance apps that sit between your machines and your ERP.
  • Machine data comes in over OPC UA, MQTT or Modbus through an edge gateway, so nothing on the line has to be replaced.
  • AI is added where it pays back first: predictive maintenance on critical assets and vision inspection on high defect stations.
  • We integrate with SAP S/4HANA, Microsoft Dynamics, Oracle and Epicor so production, inventory and finance agree.
  • A focused first release, such as a live OEE dashboard for one line, usually ships in 8 to 12 weeks.

Industry challenges we solve

Most plants do not lack data. They lack data that arrives on time, in one place, in a form a supervisor can act on during the shift rather than in next month's report.

OEE calculated in a spreadsheet. Downtime reasons are typed in at the end of the shift, from memory. By the time anyone sees the number, the shift that caused it has gone home and the root cause is a guess.
Machines that speak five protocols. A newer line on OPC UA, an older one on Modbus, a few machines with no network at all. Every integration project starts with weeks of discovery that nobody budgeted for.
ERP that does not know what the floor did. Production orders are confirmed in the ERP hours after the work finished, so inventory, costing and promise dates are all wrong in the same direction.
Paper travellers and clipboard quality checks. When a customer reports a defect, tracing which batch, machine, operator and material lot was involved takes days of searching through paper and email.
Maintenance that is either too early or too late. Calendar based servicing replaces healthy parts, while the asset that actually fails gives warning signs in vibration and temperature data nobody is watching.
Pilots that never leave the pilot line. An IIoT or AI proof of concept works on one machine, then stalls because it was never designed for security review, scale or the plant's own IT team to run.
Capabilities

Our manufacturing software capabilities

We build the layer between the machines and the ERP, then add analytics and AI on top of data you can trust.

IIoT data platform

Edge gateways collect PLC and sensor data over OPC UA, MQTT, Modbus and Siemens S7, normalise it to an ISA-95 asset model and stream it into a time series store. Buffering at the edge means no data loss when the network drops.

OEE and production dashboards

Live availability, performance and quality per line, shift and SKU, with operator downtime reason capture on a tablet at the machine. Andon style alerts when a line drops below target.

MES and work order apps

Digital work instructions, production order execution, material consumption, labour booking and genealogy. Built as focused modules so you can replace paper one process at a time.

Quality and traceability

In process checks, SPC charts, non conformance and CAPA workflows, and full batch and serial genealogy from raw material lot to shipped unit. A recall query that took days takes seconds.

Predictive maintenance

Condition monitoring on vibration, temperature and current, anomaly detection models trained on your own asset history, and work orders raised automatically in your CMMS or SAP PM.

Computer vision inspection

Camera based defect detection on stations where manual inspection misses or slows the line. Models run at the edge, flag parts for human review and improve from every confirmed defect.

How we deliver

From one line to the whole plant

  1. 01
    Plant walk and data audit

    We map machines, protocols, networks and the decisions each role makes per shift. Output: a written architecture and a short list of use cases ranked by value and data readiness.

  2. 02
    Connect one line

    Edge gateway, data model and a live dashboard for a single line, running in parallel with current reporting so the numbers can be checked against reality.

  3. 03
    Close the loop with ERP

    Production confirmations, consumption and quality results flow to the ERP automatically. Supervisors get alerts and tablets, not more reports.

  4. 04
    Scale and add AI

    Roll the template to further lines and sites, then add predictive maintenance and vision where the data now supports it. Your team is trained to run it.

Compliance and security considerations

Operational technology security and product traceability are where manufacturing software is most often audited. We design for both from the first release.

IEC 62443 aligned OT security ISA-95 data model ISO 9001 traceability support IATF 16949 support (automotive) FDA 21 CFR Part 11 (regulated plants) GDPR and UK GDPR NIS2 awareness (EU)

OT and IT stay separated. Edge gateways sit in a DMZ between the control network and the business network, push data outward only, and never accept inbound connections from the internet. We follow the zones and conduits approach of IEC 62443 and document it for your security team.

Traceability is designed in, not bolted on. Every material movement, process parameter and quality result is stored against the batch or serial number with a user and timestamp, so quality audits and customer complaints can be answered from the system rather than from paper.

Regulated plants get electronic records controls. Where FDA 21 CFR Part 11 or EU GMP Annex 11 applies, we add audit trails, electronic signatures, access controls and validation documentation to the scope from the start.

Tech stack we use for manufacturing

Open protocols at the edge, proven time series storage in the middle, and integration adapters for the ERP and maintenance systems you already run.

OPC UA MQTT and Sparkplug B Modbus and Siemens S7 Node-RED and custom edge services Azure IoT and AWS IoT TimescaleDB and InfluxDB Grafana and React dashboards Python and PyTorch ONNX Runtime at the edge SAP S/4HANA integration Microsoft Dynamics 365 Kubernetes and Docker
FAQ

Common questions

No. We connect what you have through an edge gateway that speaks OPC UA, Modbus, Siemens S7 and MQTT. Machines with no network at all can be retrofitted with low cost sensors for cycle counts, power and vibration. Replacing equipment is almost never the first step.
It depends on how standard your processes are. If an off the shelf MES fits 80 percent of your workflows, we integrate and extend it. If your processes are a competitive advantage or the product would force you to change how you work, we build focused MES modules such as work orders, genealogy and quality, one at a time.
Through the ERP's supported interfaces: OData and BAPI or IDoc for SAP S/4HANA, and the standard APIs for Dynamics 365, Oracle and Epicor. Production confirmations, goods movements and quality results post automatically, with a retry queue so nothing is lost if the ERP is down.
Often yes, but only on the right assets. We start with the few machines where an unplanned stop costs the most, confirm there is enough sensor history to learn from, and prove the model against real failures before rolling it wider. If the data is not there yet, we say so and start collecting it.
Usually 8 to 12 weeks for a first line. That covers the data audit, edge connection, a live OEE dashboard and downtime capture for one line. Plant wide rollouts and ERP integration follow in further phases sized from what the first line teaches us.
You do. Every engagement includes full IP assignment and an NDA, the code lives in your repositories, and data stays in your own cloud or on premise environment.
Free consultation, no commitment

Ready to connect your shop floor?

Tell us about your plant. Written scope, timeline and cost estimate within 48 hours.

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