Smart factory software
built for the production floor.
Manufacturing operations run on process discipline that software must respect, not disrupt. We build MES, quality management systems, production planning tools, and IIoT integration platforms for discrete and process manufacturers engineered for the operational reliability the factory floor demands.
Manufacturing software built for the shop floor, not just the requirements document
Manufacturing software projects fail in a specific way: the system works as specified but does not get used. Operators find workarounds. Paper processes persist alongside the digital system. The data quality degrades because the people who capture it do not see value in entering it accurately.
Our manufacturing software development approach addresses this before it occurs. We spend the discovery phase on the production floor observing actual workflows, understanding device and connectivity constraints, and designing for the operators who will use the system daily.
Industry 4.0 that starts with data quality, not dashboards
Most Industry 4.0 initiatives begin with a vision of real-time dashboards and discover that the underlying data is not structured or reliable enough to support meaningful analytics. We design the data collection layer first: ensuring downtime is categorised consistently, production counts are accurate, and quality results are structured before building the analytics layer.
OT/IT integration that production management can trust
Connecting enterprise IT systems to the production floor requires a security architecture that does not create risk in the process control network. We design IIoT integration with unidirectional data flows from OT systems, network segmentation maintaining the production network boundary, and interface protocols the OT team can understand and maintain.
Specialisations & capabilities
Production tracking, work order management, labour reporting, machine downtime recording, and WIP visibility connecting ERP planning to shop floor execution in real time with the audit trail ISO 9001 and customer quality audits require.
Non-conformance management, CAPA tracking, supplier quality management, inspection plan management, and document control designed to meet ISO 9001, IATF 16949, and AS9100 requirements.
Overall Equipment Effectiveness dashboards providing real-time and historical visibility into availability, performance, and quality with downtime Pareto analysis, loss categorisation, and trend alerts that drive improvement.
Platforms collecting and analysing data from production equipment, IoT sensors, and environmental monitors providing real-time dashboards, anomaly alerts, predictive maintenance signals, and energy management analytics.
Finite capacity scheduling tools, production sequence optimisation, material requirements analysis, and what-if scenario planning bridging the gap between ERP MRP output and realistic shop floor scheduling.
Operator-facing mobile applications for quality inspections, process confirmations, work order completion, and machine downtime recording designed for touchscreen use on the production floor with or without WiFi coverage.
How every engagement runs
We spend time on the shop floor observing actual workflows, production sequences, and quality checkpoints before designing any software that will support or disrupt them.
MES data model, ERP integration design, and OT connectivity architecture documented and reviewed before development begins.
We develop and deploy in phases by production area, validating each deployment against real shop floor usage before extending to the next area.
Operator training designed for the production floor context. Support during the critical first production runs to resolve real-world friction points before full handover.
Numbers that reflect real outcomes
Tools we use in production
Building manufacturing software that works on the production floor, not just in the boardroom?
Book a free discovery call with our manufacturing team. We will review your current systems landscape and design an approach that works with your production environment rather than against it.
What separates manufacturing software that gets used from software that gets worked around?
Manufacturing software development with large ERP vendors often produces systems designed for the median factory rather than your specific production environment. The result is systems with features you do not need and missing the specific workflows your process requires, leading to configuration work, custom development on a rigid platform, or the parallel paper processes that indicate a failed implementation.
Our approach to MES development starts with a manufacturing process review. We observe production workflows, interview operators, analyse current data sources, and identify where actual value-creation opportunities are before proposing any solution.
Quality management software for ISO 9001 and IATF 16949 environments requires a data model supporting the specific non-conformance classification structures, CAPA workflow requirements, and supplier audit documentation that automotive and manufacturing quality systems demand.
Connecting the production floor to enterprise systems practically
Industry 4.0 implementation for most manufacturers begins with the unglamorous work of making machine data reliable and production records structured. The OEE calculation that should be automated is being done in a spreadsheet because machine downtime records are hand-entered with inconsistent categorisation. Addressing foundational data quality first produces real operational improvement.
IIoT platform development for manufacturing requires navigating the protocol landscape of the production floor. OPC-UA is the modern standard but legacy machines may expose data only through Modbus TCP, MQTT, or proprietary vendor APIs. We design data collection architectures that handle heterogeneous sources gracefully.
ERP integration for manufacturing software is where many MES projects encounter their most significant technical challenges. SAP PP, Microsoft Dynamics 365 Manufacturing, and Oracle Manufacturing Cloud each expose production order and BOM data through different APIs with different update latency characteristics.
Accurate OEE monitoring requires capturing availability from downtime events with categorised reason codes, performance from production count and cycle time data directly from machine PLCs, and quality from inspection data rather than end-of-shift batch entry. We design OEE data collection to these requirements and validate the measurement system against manual counts before go-live.
Advanced Planning and Scheduling tools that model machine capacities, tooling changeover times, operator skill requirements, and material availability produce schedules operators can actually follow. This reduces the gap between planned and actual production that drives expediting costs and schedule instability.
Quality management software integrated with MES and ERP produces significantly better quality intelligence. Non-conformance records linked to specific production orders identify the machine, operator, and time window of a defect enabling root cause analysis that paper-based NCR systems cannot support.