We wire up machines and PLCs, capture production data in real time, and carry it from the shop floor up to the management system.
Your machines are counting. They know how many hours they ran, how many pieces came out, when they stopped and for how long. Yet at the end of the shift, the number that reaches management is a number copied by hand — filtered through memory, rounded off, and a full shift late. Our job is to close the gap between those two points.
Where a machine has a PLC and allows access, we read the registers directly over OPC UA, Modbus TCP/RTU or the Siemens S7 protocol. This is the cleanest route: no change to the control program, no effect on operation.
Many larger machines ship with their own management software and database. We read straight from it, syncing through a bridge that runs inside the factory network so no port needs opening to the outside.
Where a machine offers no usable signal, we add sensors — piece counters, vibration, indicator-lamp state — and design and build the boards and wiring systems ourselves to carry that signal back. Sensors are bought to the right specification; the interfacing and signal processing is our work.
Every factory has one: an older imported machine, technical documentation lost, supplier no longer reachable. This is usually why projects stall — because nobody will commit to getting the data out.
We write the connectivity layer for each machine type ourselves rather than buying middleware. On a machine with no documentation we can still observe the signals, compare them against what the machine actually does, and reconstruct the data structure. This is a situation we meet often and have solved on many different machine types.
Even a twenty-year-old machine usually has a signal worth taking; nobody has taken it yet.
Machine by machine, we establish which signals can be captured, how, and what each one tells you about production.
Installing the equipment needed, writing the connectivity layer, and building a stable link from the shop floor to the server, with buffering so nothing is lost when the network drops.
Screens that let operators and team leaders see machine status immediately rather than waiting for a report. We build the display software; the hardware is ordinary commercial television, so the factory can buy and replace it themselves.
We train the maintenance team to handle the common faults themselves, so the factory is not dependent on us for day-to-day work.
We do the survey, board design and manufacture, sensor interfacing and software ourselves — so the core of each project stays under our control rather than waiting on a third party's schedule.
For specialised items outside that scope we work with other IoT solution providers, so the factory receives a complete solution instead of having to stitch several suppliers together itself.
Machine data flowing into your manufacturing system, or standing on its own if you do not have one yet. From there you get equipment effectiveness, downtime by cause, and real output by shift.
This page is about data taken from machines. If you need to track materials and finished goods moving through the plant, see RFID Solutions.
We survey your factory and answer machine by machine — which ones can be read today, which need extra hardware.
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