Manufacturing & Industry 4.0
Manufacturing Software Development — MES, IIoT, Predictive Maintenance & Digital Twin
Manufacturing software is where the cloud meets the shop floor — and most of the failures are in the gap between them. We build the MES, IIoT, and predictive-maintenance layers that survive contact with real plants, real PLCs, and real OT-security constraints.
What we hear from Manufacturing & Industry 4.0 teams
- SCADA / historian data lands in the cloud weeks late and reconciled wrong — every dashboard tells a different story
- Predictive-maintenance pilots that show 90% accuracy in notebooks but never make it past one line
- OT/IT security gap: the network engineer wants air-gapped, the data team wants real-time, and the auditor wants both
- Dashboards proliferating across plants because nothing standardises the data model
- Legacy PLCs that don't speak modern protocols — and rip-and-replace isn't on the table this year
- Quality data trapped in paper / Excel because the MES never modelled the actual workflow
Regulation & compliance we work with
ISA/IEC 62443 (industrial cybersecurity)
ISO 27001 + NIST CSF
ISA-95 (enterprise-control system integration)
21 CFR Part 11 (pharma + regulated manufacturing)
GDPR (workforce + production data)
Regional industrial-safety frameworks (OSHA, EU Machinery Directive)
Data-residency for sovereign-manufacturing programs
What we deliver
MES modules: work-order execution, traceability, OEE, downtime analysis — built around the plant's actual workflow, not the textbook one
IIoT data pipelines: OPC UA / MQTT / Modbus ingestion → time-series store → dashboards + alerts
Predictive-maintenance services with feature pipelines, drift monitoring, and a real path from POC to per-line deployment
Digital-twin platforms backed by IFC / industry-vertical data models
OT/IT integration with proper segmentation (DMZ, jump hosts, signed updates)
Shop-floor mobile / tablet apps with offline-tolerant workflows
Integration with ERP (SAP, Oracle, Microsoft Dynamics) and PLM systems
FAQ
- Do you work with legacy PLCs and protocols, or only modern OPC UA?
- Both. The reality on most shop floors is a 20-year span of equipment, so our IIoT adapters cover OPC UA, MQTT, Modbus, Profinet, and serial protocols via gateway devices when the PLC predates Ethernet. We treat the protocol diversity as a constraint to design around, not an obstacle to ripping out.
- How do you handle OT-security constraints?
- We design to ISA/IEC 62443 zone-and-conduit models from the start. Production networks stay segmented; cloud connectivity goes through a hardened DMZ with signed binaries and unidirectional patterns where required. We've worked with OT-security teams on greenfield builds and on retrofits where the existing network had to be respected.
- Why do most predictive-maintenance pilots fail to scale, and what do you do differently?
- Three reasons: data drift between plants, feature-pipeline brittleness, and unclear ownership when an alert fires. Our predictive-maintenance work always includes drift monitoring, a clear alert-routing pattern (who acts, how fast, with what authority), and per-line calibration tooling so adding the next line takes days, not months.
- Can you replace our MES, or is this brownfield work only?
- Both. Brownfield (extending an existing MES with custom modules) is the lower-risk path and what we recommend in most cases. Full MES replacement is a 12–24 month engagement that we'll only quote after a written audit of the existing system, downtime tolerance, and change-management capacity — these decisions have killed manufacturers, and we won't recommend one lightly.