Production
Parts, cycles, progress and forecasts by shift.
Custom manufacturing software
Custom software that connects production and operations
We design systems that turn data from machines, operators and processes into useful information during the shift. Production, quality, maintenance and leadership can work from the same operation, with current data and rules adapted to the plant.
Plant · injection floorPLC · Modbus TCP · --:--
Shift target: 4,500 · 0 At this pace the shift closes at 0−4,500 parts under target
Press · OEE 0%Shift stoppages
- Hydraulic failure0 min
- Material shortage0 min
- Mold change0 min
- Process adjustment0 min
Interactive demo · sample data
Live production
What happens on the floor reaches the people who can act
We can read cycles from the PLC, combine them with operator input and turn them into progress, forecasts, downtime causes and alerts during the shift.
- 01Automatic reading when a suitable interface is available
- 02Brief input for causes and exceptions
- 03Forecast that changes with the actual pace
Beyond OEE
The system can grow around the operation
Production is one part of the flow. We can connect orders, materials, quality, maintenance, tooling, model changes and reporting so each area enters data once and it keeps moving.
Quality and scrap
Inspections, causes, evidence and releases.
Downtime
Duration, reason, recurrence and owners.
Maintenance
Preventive tasks, faults, spare parts and availability.
Materials
Lots, consumption, waste and links to orders.
Molds and tooling
Use, changes, life and process conditions.
Orders
Priority, product, quantity and due date.
Traceability
Machine, shift, operator, lot and inspections.
Shift reporting
Results, events, causes and pending items.
Alerts
Relevant conditions during operations.
Economic impact
Existing capacity can also be used more effectively
Recurring downtime, cycles above standard, scrap and long changeovers consume installed capacity. Measuring them by machine, shift, product and cause helps the team prioritize where to act.
SIM / MANUFACTURA
OEE recovery scenario
Adjust the assumptions and compare current productive value with a selected improvement.
Current OEE68.9%
Current productive value$1,388,028
Additional monthly scenario$60,480
Annual scenario$725,760
Illustrative scenario. Actual value depends on process, mix, demand and the plant's capacity cost.
Quality and traceability
Every lot can retain its history
We can connect order, machine, shift, operator, parameters, inspections, scrap and material lot. When a deviation appears, the team can trace what happened and which production was related.
- 01OrderOT-4821
- 02MaterialPP-H40 · L-0918
- 03MachineInjection press 03
- 04ShiftShift 2 · Laura M.
- 05InspectionDimension and appearance
- 06Result98.2% good parts
Maintenance connected to production
Machine history helps decisions before the next downtime event
We can record faults, preventive maintenance, spare parts and downtime, then connect them with actual production data to identify recurring issues and critical equipment.
EventDateDowntime
High temperatureSep 246 min
Hydraulic leakAug 1882 min
Mold sensorAug 431 min
159 accumulated min · recurring pattern on shift 2
Shop-floor integrations
We review how every machine and system communicates
PLCs, digital signals, OPC UA, Modbus, EtherNet/IP, databases, ERP and tablet input can coexist in a project. We first review equipment, network and protocols, then define the appropriate architecture.
IN / 01PLC / machineIN / 02Digital signalsIN / 03Operator input
CORE / FLOWGateway / edge
OUT / 01PlatformOUT / 02Tablet and dashboardOUT / 03ERP and reports
The final connection depends on the available controller, protocol, network, licenses and technical access.
Project example
Example: 14 machines and three shifts
We could begin with the machines that most affect capacity, validate cycle readings and downtime causes, then extend the system into quality, maintenance and materials. Scope and schedule are defined with the plant.
Illustrative roadmap · sequence is defined with the plant- 01Discovery→
- 02Pilot · 4 machines→
- 03Validation→
- 04Expansion→
- 05New areas
Questions before getting started
What to define in the first review
Scope is built around operations, data and the available technical conditions.
Q/01Do you need to modify my machines?
The available interface decides it. We review PLCs, protocols and signals before defining the connection. For equipment without a useful interface, we can evaluate reading alternatives that leave machine control intact.
Q/02Is it only for injection molding machines?
We can work with lines, presses, lathes, assembly and other processes where a signal, controller or operating input can represent the cycle.
Q/03How much does it cost?
Cost is set by the number of machines, data sources, integrations and processes. The first step is a review at no cost: we reply within one business day and, after the review, send you scope, timeline and cost in writing. The proposal compares that cost with the losses we can measure in the operation.
Q/04Can it grow into quality and maintenance?
Yes. We design the architecture to add processes, equipment and areas in stages while maintaining a consistent source of information.
Let's review where to connect your plant first
We can review machines, processes and shift decisions to define a first scope that delivers useful information to production and related areas.
First review at no cost · Written scope and integrations