One platform instead of disconnected production systems

How we replace dated, disconnected systems with one production platform.

This is an example of how we work, using an illustrative company. It shows our approach, but it isn't a specific client project.

Methodology exampleManufacturers running dated, disconnected systemsManufacturingCustom softwareMulti-month engagement

The challenge

Manufacturers often run systems that don't connect: a dated MES, a separate quality system, and reports for management built by hand. Data gets retyped from one system into another, so errors creep in, and there's no live view of what's happening on the floor.

Separate, dated systems with data moved by hand between them

A lot of time lost to manual data entry on each line

Quality problems get caught too late

Management reports that are out of date

Our approach

We roll out the new platform line by line, without stopping production. On the shop floor, we pull in machine data that wasn't available before.

Process & system review

First phase

We map every production process, data flow, and connection to existing systems.

Platform setup

We design the platform with an OPC-UA connection, real-time dashboards, and work orders on mobile.

Rollout per production line

Main phase

Line by line, running alongside the old system to keep risk low and train operators.

Optimization & predictive maintenance

Wrap-up

Using past data, we predict maintenance needs and fine-tune production.

What this approach delivers

The approach does away with retyping data by hand, surfaces quality problems sooner, and gives management a live view of production. What it delivers depends on how complex the production environment is and where you start.

Technologies used

OPC-UAEdge ComputingReal-time DashboardsReact / Next.jsPythonTimescaleDB

Whitepaper

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Owner's guide

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