Loading
Industrial IoT & Smart Factory
Connect the shop floor to systems that act on it
Sensors, PLCs, and SCADA on one data layer — with edge gateways, historians, and OEE dashboards that make machine behavior visible to the people running the plant. Engineered for brownfield plants
SCADA
PLC & Controller Integration
Edge
On-Site Gateways
OEE
Availability · Performance · Quality
MQTT
OPC UA & Protocol Bridging
Core Capabilities
What We Build On The Floor
From controller tags to plant dashboards — the connectivity, storage, and integration layers of a smart factory.
Machine Connectivity & Protocol Bridging
Get data out of mixed-vintage equipment — PLCs, CNC controllers, meters, and standalone sensors — and onto one normalized stream.
- OPC UA, Modbus and MQTT bridging
- PLC and CNC controller tag mapping
- Retrofit sensors for unconnected assets
- Unified tag naming across lines
Edge Gateways & Local Buffering
On-site compute that collects, filters, and buffers machine data, so the line keeps recording when the uplink drops out.
- Store-and-forward on link loss
- Local filtering & aggregation
- Edge inference for latency-bound checks
- Remote gateway configuration
OEE & Production Dashboards
Availability, performance, and quality computed from machine signals rather than manual logs — visible on the floor and in the office.
- Availability, performance, quality split
- Downtime reason capture & coding
- Shift, line and plant rollups
- Andon and floor-facing displays
Historian & Time-Series Pipelines
Machine telemetry stored at the resolution engineers need, with retention tiers and query access for analysis and reporting.
- Time-series storage & downsampling
- Retention tiering by signal value
- Contextualized batch and order tags
- APIs for analytics and BI tools
Condition Monitoring & Alerting
Thresholds, trends, and models over vibration, temperature, current, and cycle data to flag equipment drifting out of normal.
- Vibration and thermal trending
- Rule and model-based alerts
- Escalation into maintenance workflows
- Alarm rationalization and noise control
MES & Business System Integration
Close the loop between floor and office by linking machine events to work orders, inventory, quality records, and ERP.
- Work order and batch context
- Quality event and scrap capture
- ERP and inventory synchronization
- Traceability from order to machine
Use Cases
Where Shop-Floor Data Pays Off
Applications that start with one line and extend across sites.
Real-Time Line Monitoring
Live machine status, cycle counts, and stoppages across every line, replacing whiteboards and end-of-shift paperwork.
Live machine stateCycle countingStoppage capture
Designed to make downtime visible while it is still happening
Predictive Maintenance Pilots
Instrument critical assets, build a normal-behavior baseline, and trend toward failure indicators before scheduling logic changes.
Sensor retrofitBaseline modelingFailure indicators
Built to move maintenance from calendar-based to condition-based
Energy & Utility Monitoring
Sub-metering across lines, compressors, and utilities to attribute consumption to assets, shifts, and production volume.
Sub-meteringPer-asset attributionLoad profiling
Designed to attribute energy cost to the assets that spend it
Process & Environment Compliance
Continuous logging of temperature, humidity, and process parameters, with tamper-evident records available for audits.
Continuous loggingExcursion alertingAudit-ready records
Engineered for continuous evidence instead of spot readings
Traceability & Genealogy
Tie each batch or serial number to the machines, settings, operators, and materials involved in producing it.
Batch-to-machine linkageParameter captureRecall scoping
Built to narrow a recall to the batches actually affected
Multi-Plant Consolidation
Roll standardized metrics from several sites into one view, while each plant keeps local autonomy and local buffering.
Standard metric definitionsPer-site edge autonomyGroup-level rollups
Designed to compare plants on identical definitions
Key Benefits
How We Approach Industrial Deployments
Engineering choices designed for real plants with real constraints.
SCADA
Works With What You Own
Integration built for mixed-vintage brownfield equipment rather than assuming a fleet replacement.
Edge
Keeps Recording Offline
Local buffering designed so a dropped uplink costs you connectivity, not the production record.
OEE
One Set of Definitions
Availability, performance, and quality computed the same way on every line and every shift.
OT/IT
Segregation Respected
Designed to move data north from the control network without opening a path back into it.
Our Process
From Plant Walk to Rollout
A pilot-first sequence that proves the data path before anything scales.
Step 01
Plant Walk & Asset Survey
Walk the floor to catalogue controllers, protocols, network layout, and which signals actually exist today.
Step 02
Pilot One Line
Instrument a single line end to end, prove the data path, and validate metric definitions with the people who use them.
Step 03
Roll Out & Integrate
Extend to the remaining lines and sites, then connect machine events to MES, maintenance, and ERP workflows.
Step 04
Operate & Extend
Hand over dashboards and runbooks, tune alarms against real noise, and layer analytics once the data is trusted.
FAQ
Smart factory questions, answered
How we connect machines, respect OT boundaries, and roll out across plants.
Will this work with our older machines?
Usually, yes. Machines with a PLC or controller can often be read over OPC UA, Modbus, or a vendor protocol. Genuinely unconnected assets get retrofit sensors — current clamps, vibration pucks, proximity and cycle counters — mounted without altering the machine. We survey the floor first and tell you which assets fall into which category before quoting a rollout.
How does this relate to your manufacturing industry solutions?
Our manufacturing industry page describes outcomes for the sector as a whole, including supply chain, workforce, and MES. This page is the engineering layer beneath the shop-floor half of it: getting signals off machines, moving them safely across the OT/IT boundary, storing them, and turning them into OEE and condition metrics.
Do you need to open our control network to the internet?
No. The standard pattern is a one-way northbound flow: an edge gateway on the OT side reads from controllers and publishes outward through a controlled boundary, with no inbound path back into the control network. Where remote support is needed, it runs through a brokered, logged session rather than a permanent tunnel.
What happens when the network or internet connection fails?
The edge gateway buffers locally and forwards once the link returns, so the production record has no gap. Floor-facing dashboards served from the gateway keep working during an outage, since operators need the display most when other things are already going wrong.
Can we start with one line instead of the whole plant?
That is the approach we recommend. A single-line pilot proves the protocol path, the metric definitions, and the operator workflow at a fraction of the cost of a plant-wide commitment — and it surfaces the awkward assets early, while the scope is still small enough to change.
Who defines what counts as downtime or a good part?
You do, and we write it down. OEE is only comparable if availability, performance, and quality use one agreed definition — planned versus unplanned stops, micro-stoppage thresholds, how rework is treated. We facilitate that agreement between production and maintenance during the pilot, then encode it once so every line reports the same way.
Get started
Ready to see what your machines are doing?
Start with one line. We survey the assets, prove the data path, and agree the metric definitions before anything scales.
No commitment required
Free consultation
Expert support