Software for Manufacturing
The shop floor is where software goes to be ignored. We build for gloves, dust, patchy Wi-Fi, and a supervisor who will go back to the register the moment a screen is slower than a pen.
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{ 01 } — How we work in Manufacturing
Built for gloves, dust, and deadlines.
We design on the floor, not at a desk: barcode-fast logging, offline tolerance, and dashboards that answer the 9 AM meeting.
Walk the floor
- Process & station mapping
- Data capture points
- KPI definition
Digitize
- Production & job tracking
- Inventory & materials
- Quality checks & NCRs
Improve
- Downtime & OEE dashboards
- Exception alerts
- ERP & Tally sync
You cannot improve what you cannot see. Within weeks the system shows real WIP, real downtime, and real wastage — the honest baseline every improvement is measured against.
That baseline is almost always worse than the one management believes, and that is the point. A plant that discovers its real OEE is eleven points below the reported figure has found the improvement, not lost one.
For what we build — the modules, the integrations, the stack — see the Manufacturing IT service page. This page is about the other half: what a working floor does to software after it is installed, which is where these projects are actually won or lost.
{ 03 } — What we build
What we build for manufacturing.
Production tracking
Jobs, batches, and stations logged live from the floor.
Inventory & materials
Raw material to finished goods with reorder alerts.
Quality & compliance
Inspections, NCR workflows, and audit-ready records.
Maintenance
Preventive schedules and breakdown logging that protect uptime.
{ 04 } — What makes it hard
The floor rejects software before it evaluates it.
Plant systems rarely fail on functionality. They fail on the four frictions below, all of which are invisible from a conference room and obvious within an hour of standing at a station.
Every capture point competes with a pen
An operator logging a batch has a few seconds between units. If the screen takes longer than the register did, logging moves to the end of the shift and becomes recollection. Scan-first interfaces are not a preference here, they are the requirement.
The network stops at the shed door
Steel structures, moving machinery, and cost-driven Wi-Fi coverage mean connectivity is intermittent by default. Anything that assumes a live connection to record work will lose records, and the loss is discovered at month-end.
Machines predate the internet
A press from 2004 has no API and may have no port. Getting data out means OPC UA where it exists, PLC tapping, retrofit sensors, or an operator entry — and choosing honestly between them per machine rather than pretending the fleet is uniform.
The unit of work keeps changing
Jobs split, batches merge, rework re-enters the line mid-process, and a rejected unit consumes material that was already booked to a finished order. Systems that model production as a queue of identical units cannot represent any of it.
{ 05 } — What you have to get right
Traceability is a legal position, not a report.
For anything under a BIS standard, exported, or supplied into automotive or pharmaceutical chains, the question is not whether you track quality but whether you can reconstruct a specific unit's history on demand — which materials, which machine, which operator, which inspection, on which date. That capability has to be designed into the capture points; it cannot be derived later from summary data.
The statutory side is more mundane and just as unforgiving. Production and inventory movements feed GST records including e-invoicing and e-way bills, and a floor system whose numbers do not reconcile to the accounting system creates a discrepancy that surfaces during assessment rather than during the month.
- Batch and serial genealogy from raw material through dispatch
- Non-conformance records with disposition, rework history, and sign-off retained
- GS1-standard identification where goods leave your premises
- Calibration and preventive-maintenance records tied to the machine, not a spreadsheet
- Stock movements reconciling to the accounting system daily, not at close
- Operator identity on every entry, so a traceability query has an answer
How we help here
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Frequently asked questions
Yes — capture points buffer offline and sync when the network returns.
That is the design bar: scans, big buttons, one decision per screen — faster than paper or it gets redesigned.
Yes — production and inventory data flow into your accounting and ERP automatically.
We survey the fleet machine by machine and pick per machine, not per plant: OPC UA or Modbus where the controller supports it, retrofit sensors for run-time and counts where it does not, and an honest operator entry where neither is worth the cost. Pretending a mixed fleet is uniform is how these projects stall.
Six to ten weeks for one line, and the first number is usually lower than the reported one. That gap is the finding — it means the losses were being absorbed somewhere rather than measured, and it is the baseline every improvement afterwards is proved against.
{ Sources }
Standards and regulators referenced here
- OPC UA — industrial interoperability standard — OPC Foundation
- BIS — Indian standards — Bureau of Indian Standards
- GS1 — global standards for product identification and barcodes — GS1
- GST portal — invoicing, returns, and e-invoice requirements — Goods and Services Tax Network