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.
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
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.
We build the layer between the machines and the ERP, then add analytics and AI on top of data you can trust.
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.
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.
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.
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.
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.
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.
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.
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.
Production confirmations, consumption and quality results flow to the ERP automatically. Supervisors get alerts and tablets, not more reports.
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.
Operational technology security and product traceability are where manufacturing software is most often audited. We design for both from the first release.
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.
Open protocols at the edge, proven time series storage in the middle, and integration adapters for the ERP and maintenance systems you already run.
Tell us about your plant. Written scope, timeline and cost estimate within 48 hours.