Manufacturing and industry: Make every station on the production line measurable.
We build manufacturing execution systems (MES), computer vision quality control, predictive maintenance and IoT solutions for factories and industrial companies, and integrate them with ERP and SAP. The goal is to turn shop floor data that stays on paper or inside machines into live, reliable information you can act on.
Typical needs
Digitising shop floor data, quality and efficiency
Illustrative interface
Industry challenges
Problems we often see in this industry
Shop floor data on paper
When output, downtime and scrap are written on forms at the end of a shift, data arrives late, incomplete and disputed.
Quality control by eye
Visual inspection on busy lines is prone to fatigue; a defective product that reaches the customer multiplies the cost.
Unplanned downtime
When failures are noticed only once a machine stops, maintenance stays reactive and delivery plans slip.
Machines that do not talk
Machines from different eras and brands use different protocols, which makes collecting data in one place hard.
Gap between ERP and the floor
The difference between the work order in the ERP and what was actually produced only shows up at stock count.
Our solutions
What we build
Production tracking (MES)
Production tracking software that collects work orders, station, downtime, scrap and shift data in real time and calculates OEE and efficiency per line.
Computer vision quality control
AI models that detect scratches, missing parts or wrong labels in images from line cameras and divert suspect products.
Predictive maintenance
Models that spot early signs of failure in vibration, temperature and current data and alert the maintenance team.
IoT
Embedded software and gateways, on site and in the cloud, that collect data from PLCs, sensors and machines over OPC UA, MQTT or Modbus.
ERP and SAP integration
Work orders, material consumption and production confirmations flowing two-way with ERP and SAP, without manual steps.
Related services
The services behind these solutions
Custom Enterprise Software
ERP, CRM, WMS and workflow software built around your processes, with your systems connected.
Machine Learning and Computer Vision
Forecasting, computer vision, document processing and natural language processing models.
IoT and Embedded Software
Connected devices with firmware, device-to-cloud communication, remote updates and a management panel.
SAP Basis Consulting
SAP system architecture, installation, upgrades, S/4HANA transformation and 24/7 support.
Data, Business Intelligence and Reporting
Turn scattered data into a single source of truth with a data warehouse, ETL pipelines and dashboards.
Representative scenario
MES and vision-based quality control at an automotive supplier
Representative scenario, not a real client project.
- Profile
- An automotive parts supplier with several assembly lines, producing for vehicle manufacturers and running SAP.
- Problem
- Output and downtime were collected on forms at the end of each shift and quality control was done by eye at the end of the line. Tracing the source of customer returns was hard, and ERP stock often did not match the floor.
- Approach
- One line was chosen as a pilot; output and downtime data started flowing from machines through an IoT gateway.
- Touchscreen MES terminals made it easy for operators to enter work orders, downtime reasons and scrap.
- A camera at the end of the line fed a computer vision model trained on defect classes, and suspect parts were diverted.
- Production confirmations were sent to SAP automatically, and a rollout to other lines was planned based on pilot results.
- Solutions used
- Production tracking (MES)
- Computer vision quality control
- IoT gateway
- SAP integration
- Outcome
- Output and downtime per line became visible in real time, defective parts were separated before shipping and the gap between ERP and the floor became visible within the day.
FAQ
Frequently asked questions
What is an MES and how does it differ from an ERP?
An ERP manages business processes such as planning, purchasing, stock and finance. An MES (manufacturing execution system) tracks on the floor, at machine and station level, what was produced, when and at what quality. They complement each other; MES data flows into the ERP as production confirmations.
Can data be collected from older machines?
In most cases, yes. Machines with a PLC can be read over OPC UA or Modbus; machines without one can be fitted with sensors and IoT gateways. We decide the method for each machine during the site survey.
What does computer vision quality control require?
Suitable cameras and lighting, sample images of good and defective products and a clear definition of defect classes. We validate the model on a pilot line under real conditions before going live.
Should we digitise the whole factory at once?
We do not recommend it. A pilot on one line or a critical process reveals both technical risks and shop floor adoption early. The rollout plan is based on the pilot results.
How is integration with SAP or our current ERP done?
For SAP through standard interfaces (BAPI, IDoc, OData) or SAP BTP; for other ERPs through web services or database integration. We define together during discovery which data flows in which direction.
Let's plan the right solution for your industry
Tell us briefly what you need and we will get back to you within one business day. The first 30-minute introductory call is free.