Industry
See the shop floor as it really runs.
We build the shop-floor systems, live OEE and clean ERP and MES integration that turn scattered production data into a picture your line managers actually use.
Overview
On most shop floors the truth about production is spread thin: some of it sits in the ERP, some in the MES, some on the PLCs, and a good deal in the tally sheets an operator fills in by hand. By the time it is gathered into a report, the shift is over and the chance to act has passed. The result is a plant that runs on end-of-day numbers when it needs to see what is happening now.
We come from heavy industry ourselves, so we know that a clean OEE figure is worth far more than another glossy dashboard. We start by advising honestly on what to measure and what to leave alone, then capture data at the source, from machines where we can and from simple, fast operator inputs where we cannot. Live OEE by line, shift and cause becomes something a supervisor checks between rounds, not a monthly report argued over in a meeting.
Integration is where good intentions usually stall, so it is where we focus. We connect the shop floor to your ERP and MES cleanly, so a job, a batch and a quantity mean the same thing everywhere and nobody is re-keying numbers between systems. That same backbone carries traceability, letting you follow a batch or component through the process and answer a quality or recall question in minutes rather than days.
Industry 4.0 only pays off when it is grounded in the everyday work of the floor, so we keep it practical. We target the losses that hurt, scrap, downtime and slow changeovers, and we build in increments that prove their value early. We advise, we build and we can run the systems afterwards, so improvement continues after go-live instead of stalling the moment the project team leaves.
The reality
What we hear from manufacturing teams.
OEE calculated after the fact, if at all, so problems are seen too late to fix
Production data scattered across ERP, MES, PLCs and paper tally sheets
Scrap and downtime logged inconsistently, hiding the real cost
ERP and MES that do not talk cleanly, forcing manual re-keying and mismatches
Traceability that takes days to reconstruct when a quality question arrives
Industry 4.0 ambitions stalled on pilots that never reach the whole plant
How we help
Software and data, built for manufacturing.
Live OEE
Availability, performance and quality tracked in real time by line, shift and cause, so supervisors see losses as they happen and can act on the same shift.
Shop-floor data capture
We capture data at the source, from machines and PLCs where possible and from fast, simple operator screens where not, so the record is accurate and immediate.
ERP & MES integration
Clean, reliable links between the shop floor and your ERP and MES, so jobs, batches and quantities mean the same thing everywhere and nothing is re-keyed.
Scrap & downtime analysis
Consistent, categorised recording of scrap and downtime that exposes the true cost of each loss and points clearly at what to fix first.
Traceability
Follow a batch or component through the process end to end, so quality and recall questions are answered in minutes with a full, defensible record.
Practical Industry 4.0
We deliver connected-plant capability in grounded increments that prove value early, rather than pilots that never scale beyond one line.
How we work
People who have worked your world, not just read about it.
Advise
We walk the line with your team, agree what is worth measuring and map where data really lives, so the plan targets losses that matter and skips the vanity metrics.
Build
We deliver in working increments, capturing data at the source and integrating cleanly with your ERP and MES, proving value on one line before scaling across the plant.
Run
We can operate and support the systems, refining OEE definitions and integrations as products and processes change so the numbers stay trustworthy.
- +10-15% typical
- OEE gain once losses are visible in real time
- Live, by shift
- OEE seen as it happens, not at month end
- Minutes, not days
- To trace a batch through the process
FAQ
Questions we hear a lot.
How do you calculate live OEE on the shop floor?
We capture availability, performance and quality data at the source, reading from machines and PLCs where possible and using fast operator inputs where automation is not practical. That feeds a live OEE view broken down by line, shift and cause. Because it is real time and honest, supervisors can act on a loss during the shift rather than reading about it in a report the following week.
Can you integrate shop-floor systems with our existing ERP and MES?
Yes, and clean integration is central to how we work. We build reliable links so that a job, batch and quantity carry the same meaning across the shop floor, MES and ERP, which ends the manual re-keying and the mismatches it causes. We integrate around the systems you already run rather than forcing a rip-and-replace.
What does traceability give us in practice?
It lets you follow any batch or component through the process from start to finish, with a complete and defensible record. When a quality issue or recall question arrives, you can answer it in minutes instead of spending days reconstructing what happened. The same data also helps you find where scrap and rework are really being created.
How do you approach Industry 4.0 without an expensive failed pilot?
We keep it grounded in the everyday work of the floor and target the losses that actually hurt, such as scrap, downtime and slow changeovers. We build in increments that prove their value on one line before scaling, so investment follows evidence. That avoids the common trap of a pilot that looks impressive but never reaches the rest of the plant.
Working in Manufacturing? Let's talk.
Tell us what you are trying to fix. We will tell you how we would approach it, and whether software is even the right answer.