Fewer unplanned stops, and a reason for each

What actually goes wrong on the floor

• Predictive maintenance

  Vibration, temperature and motor-current tags from the historian, modelled per asset, so a bearing warning names the machine and the downtime code it prevents.

• Vision inspection

  Line-scan or area cameras running edge inference at takt time, checking every unit against the defect classes your nonconformance reports keep recording.

• OEE and downtime analytics

  Availability, performance and quality calculated identically on every line, with each stop attributed to a code an operator entered rather than one reconstructed a week later.

• MES, ERP and SCADA integration

  We read work orders, routings and BOMs across the ISA-95 gap between your MES and ERP, then write results back where planners already look.

• IIoT ingestion

  PLC and CNC data over OPC UA, MTConnect, MQTT or Modbus TCP, landed in a time-series store that survives a gateway dropping for an hour.

• Quality and SPC surfaces

  Control charts and Cpk on the characteristics your control plan actually names, with an out-of-spec run raising a nonconformance instead of an email someone forwards.

• Component provenance on chain

  Serial or lot-level chain of custody from supplier to assembly, for automotive, aerospace and electronics programmes where a counterfeit part becomes a recall.

• Shared quality records

  Inspection results, test data and certificates of conformance timestamped for OEMs, tier-one suppliers and auditors, so a PPAP package gets assembled rather than chased.

• Planning and supplier automation

  Demand and capacity models run against real order trends, plus RFQ parsing and PO reconciliation so planners spend the day on exceptions.

RUNNING SYSTEM

The model or cell, in production

Deployed against live tags on the line it was scoped for, with source, pipelines and the deploy path handed over. Your team can retrain it after a tooling change without booking us.

TAG DICTIONARY

Every signal, named and mapped

The mapping from PLC addresses and historian tags to what they physically measure, with units and sample rates. It is the asset that outlives the model, and almost no plant has one written down.

QUALITY BASELINE

Measured before and after

How the model or vision cell performs against labelled cases from your own production, including where it fails. Without it, a later model change gets argued about rather than measured.

OPERATING NOTES

Alerts, thresholds and escalation

Which warning reaches which shift, what threshold triggers it, and what happens when the gateway drops. Written for the maintenance planner on call, not for the data team.

1. 01

   Data and process review

   2 weeks

   We walk the line, read the historian, and check whether downtime codes and quality records are complete enough to learn anything from.

2. 02

   Pilot on one line

   8–12 weeks

   One asset or one defect class, run against your own production data. This is the step that changes the scope and occasionally ends it, cheaply.

3. 03

   Build and integrate

   4–6 months

   Ingestion pipeline, model deployment, MES and ERP write-back, and the operator surfaces, rolled to the remaining lines one at a time.

4. 04

   Run and retune

   Ongoing

   Retraining after tooling and material changes, tightening thresholds so operators stop ignoring alerts, and adding assets once the first ones have earned trust.