Job status relayed verbally between shifts
01Progress lives on whiteboards and in handover conversations, so planners and customer service can't see what's actually complete until someone walks the floor.
MANUFACTURING SOFTWARE DEVELOPMENTGive production teams a reliable view of work in progress.
We build production tracking, quality and maintenance applications that sit alongside your ERP and MES, collect operator and machine events, and tie them to the right work order, lot and work center.
Manufacturers, plant operations leaders and industrial software teams
THE OPERATIONAL GAP
Production visibility is only useful when events match work orders.
Plants rarely lack data. They lack data tied to the right order, batch and shift. These are the gaps we look for first.
Machine events not tied to work orders
02Equipment produces counts and alarms, but nothing links them to the order or lot being run, so downtime and scrap can't be costed to the right job.
Quality defects recorded apart from production batches
03Inspection results sit in spreadsheets or a separate QMS, making it slow to trace a defect back to material lots, machines and operators.
Maintenance planned without production context
04Preventive maintenance is scheduled by calendar while planners schedule by demand, causing conflicts, rushed repairs and avoidable downtime.
Job status relayed verbally between shifts
01Progress lives on whiteboards and in handover conversations, so planners and customer service can't see what's actually complete until someone walks the floor.
Machine events not tied to work orders
02Equipment produces counts and alarms, but nothing links them to the order or lot being run, so downtime and scrap can't be costed to the right job.
Quality defects recorded apart from production batches
03Inspection results sit in spreadsheets or a separate QMS, making it slow to trace a defect back to material lots, machines and operators.
Maintenance planned without production context
04Preventive maintenance is scheduled by calendar while planners schedule by demand, causing conflicts, rushed repairs and avoidable downtime.
WHAT WE BUILD
Manufacturing software we design and build.
We complement your ERP and MES rather than replacing them, filling the gaps where spreadsheets and paper still run the floor.
01
Production visibility dashboards
Live work-in-progress by line and work center, built from operator inputs and machine events tied to each work order.
02
Quality and nonconformance tracking
Inspection checklists, nonconformance reports, holds and CAPA workflows linked to lots, suppliers and production records.
03
Maintenance and asset work-order systems
Preventive and corrective work orders, spare parts and downtime records, scheduled with production plans in view.
04
MES-adjacent operator applications
Tablet apps for job start/stop, material scans, checklists and shift handovers where a full MES is too heavy or missing.
01
Production visibility dashboards
Live work-in-progress by line and work center, built from operator inputs and machine events tied to each work order.
02
Quality and nonconformance tracking
Inspection checklists, nonconformance reports, holds and CAPA workflows linked to lots, suppliers and production records.
03
Maintenance and asset work-order systems
Preventive and corrective work orders, spare parts and downtime records, scheduled with production plans in view.
04
MES-adjacent operator applications
Tablet apps for job start/stop, material scans, checklists and shift handovers where a full MES is too heavy or missing.
WORKFLOW EXAMPLE
From released order to approved production state.
An example production flow. Event sources, quality rules and approval roles are confirmed with your plant team.
Production order released
InputWork order from ERP with routing and bill of materials
OutputReleased job with operations, work centers and planned quantities
01Operator and machine events collected
InputOperator scans and machine signals via gateway
OutputTime-stamped start, stop, count and alarm events
02Events linked to work center and lot
InputRaw events and released job
OutputProduction records tied to order, lot, machine and operator
03Quality exceptions reviewed
InputOut-of-spec measurements, scrap or unexpected downtime
OutputHold, rework or release decision with inspector recorded
Review required
04Approved production state published
InputReviewed production records
OutputUpdated ERP quantities, dashboards and traceability record
05
SYSTEM DESIGN
The architecture behind the workflow.
A reference design that reads from the plant floor without taking control of machines unless that is explicitly scoped and validated.
- ERP and order data
- Shop-floor gateway or operator app
- Event ingestion and normalization
- Traceability and quality store
- Plant dashboards and alerts
- Quality exceptions reviewed
- ERP and order data to Shop-floor gateway or operator app
- Shop-floor gateway or operator app to Event ingestion and normalization
- Event ingestion and normalization to Traceability and quality store
- Traceability and quality store to Plant dashboards and alerts
- Traceability and quality store to Quality exceptions reviewed
- Quality exceptions reviewed to Plant dashboards and alerts
ERP and order data -> Shop-floor gateway or operator app -> Event ingestion and normalization -> Traceability and quality store -> Plant dashboards and alerts
01
ERP and order data
Provides released work orders, routings, bills of materials and receives confirmed quantities.
02
Shop-floor gateway or operator app
Collects machine signals through OPC UA, MQTT or PLC interfaces and operator input from tablets or scanners.
03
Event ingestion and normalization
Buffers events through network outages, removes duplicates and maps tags to machines and work centers.
04
Traceability and quality store
Links materials, lots, operations, inspections and operators for forward and backward trace.
05
Plant dashboards and alerts
Shows work in progress, downtime and quality status and alerts supervisors to exceptions.
Technology
Chosen for the systems above.
These tools are already in published projects with a similar shape of work. The set for your release is confirmed once the interfaces and review points are known.
- OPC UA
- MQTT
- Edge gateways
- ERP APIs (e.g. SAP, NetSuite, Epicor)
- Offline-capable tablet apps
Frontend
Next.jsBootstrapReduxNext.jsBootstrapReduxBackend
Node.jsExpress.jsNode.jsExpress.jsDatabase
MySQLMySQLCommunication
TwilioTwilio
DESIGN TRADE-OFFS
Decisions that change cost, reliability and scope.
Plant-floor projects are constrained by equipment age, network design and safety, so we settle these first.
Read-only telemetry versus machine control
Reading machine data is low-risk and delivers most visibility benefits. Writing setpoints or commands to equipment requires controls engineering and safety review.
Agree the boundary with your controls engineers and EHS lead in writing.
Edge collection versus cloud-only
Edge gateways buffer data during network outages and reduce latency; cloud-only is simpler when plant connectivity is reliable.
Survey network reliability and the protocols your equipment supports.
Predictive maintenance versus fixed thresholds
Failure prediction needs labeled failure history that many plants don't have. Condition thresholds and run-hour triggers often deliver value first.
Review maintenance history for consistent failure codes and sensor coverage.
Read-only telemetry versus machine control
Reading machine data is low-risk and delivers most visibility benefits. Writing setpoints or commands to equipment requires controls engineering and safety review.
Agree the boundary with your controls engineers and EHS lead in writing.
Edge collection versus cloud-only
Edge gateways buffer data during network outages and reduce latency; cloud-only is simpler when plant connectivity is reliable.
Survey network reliability and the protocols your equipment supports.
Predictive maintenance versus fixed thresholds
Failure prediction needs labeled failure history that many plants don't have. Condition thresholds and run-hour triggers often deliver value first.
Review maintenance history for consistent failure codes and sensor coverage.
SECURITY & COMPLIANCE
Controls appropriate to plant-floor systems.
We design with your OT and IT teams so new software doesn't create new paths into production equipment.
Software dashboards do not certify machinery or replace functional safety engineering. Industrial control system security should follow guidance such as NIST SP 800-82 and ISA/IEC 62443 with your OT specialists.
OT/IT network separation
Shop-floor data flows outward through a controlled gateway or DMZ; enterprise and cloud systems never connect directly to control networks.
Safety functions stay independent
Safety systems and interlocks remain independent of the software we build; our applications observe and report rather than override.
Equipment event provenance
Every event records its source device, time and transformation so production and quality records can be trusted in audits.
Operator authentication and change tracking
Operators sign in by badge or PIN, and changes to routings, specs or quality decisions are logged with who and why.
NIST SP 800-82 (OT security guidance)ISA/IEC 62443 (reference)NIST Cybersecurity Framework 2.0
NIST SP 800-82 (OT security guidance)ISA/IEC 62443 (reference)NIST Cybersecurity Framework 2.0
DELIVERY APPROACH
From real plant constraints to a verifiable release.
We start with one line or cell, prove value, then roll out with operator feedback.
01
Inventory machines and interfaces
Survey equipment, controllers, protocols, network zones and existing ERP/MES interfaces.
Signed equipment and interface inventory with connectivity options per machine.
02
Model work orders and equipment IDs
Align ERP work centers, machine tags and lot numbering.
Approved data model and identifier mapping for the pilot line.
03
Build one production-line workflow
Deliver order-to-confirmation tracking for a single line.
Pilot line tracked end to end with operators using the app on real jobs.
04
Test outages and event ordering
Simulate network loss, late and duplicate events and gateway restarts.
Test results showing no lost or double-counted production during outages.
05
Roll out line by line with operator feedback
Expand with training and adjustments from each line.
Rollout plan, training records, support owners and rollback per line signed off.
Published work
Projects you can read in full.
Each card is a published project. The industry on the card is the one that work was built for.
From the journal
Reading that sits beside this work.
Recent notes from the team. Pieces that match this industry are shown first.
PROJECT PLANNING
What we need to define before development begins.
A plant walk-through and access to your ERP data model usually answer most of these.
- 01
Which ERP and MES (if any) are in use, and which owns work-order status?
- 02
What controllers and protocols do the pilot machines use?
- 03
Will the software only read data, or must it send instructions to equipment?
- 04
What traceability do your customers or regulators require?
- 05
Which metric will judge the pilot, such as OEE visibility, scrap or downtime response?
Controls engineer and OT network access
ERP API or export access
Pilot line and supervisor availability
Plant safety and change-management approval
Controls engineer and OT network access
ERP API or export access
Pilot line and supervisor availability
Plant safety and change-management approval
Manufacturing software development FAQs.
In most cases, yes, through their APIs, database views, file exchanges or integration middleware. We map work orders, routings and confirmations in both directions and confirm vendor support and licensing for each interface first.
Many older machines can be read through existing PLC interfaces, protocol converters or retrofit sensors for cycle counts and states. Where that isn't practical, a quick operator input on a tablet often gives enough visibility.
Sometimes. It depends on having sensor data and a consistent record of past failures. We first assess your data; where it's thin, we start with condition alerts and run-hour triggers, and collect the history prediction needs.
It shouldn't. We start read-only on one line, install gateways during planned stops, run in parallel with existing processes and only switch over once supervisors have signed off.
Usually not. We fill gaps around it, such as operator apps, quality workflows or cross-plant visibility, and only recommend replacement when the existing system blocks critical needs.
You own the application and the operational records it stores. MES, ERP, and machine vendors keep their own systems. We document which system is the source for an order, a batch, and a quality result.
It can, when your network team allows the path between the application and the systems it must read. We do not assume a machine can be reached from the public internet.
One line or one process: the order status, the people who update it, and the exception that currently lives on paper or in a spreadsheet. Shop-floor control systems stay in place.
Updates are validated and queued. A failed or incomplete message is visible to an owner and can be retried. The ERP is not treated as a scratchpad.
Have a production, quality or maintenance workflow to fix?
Tell us about your plant systems and where visibility breaks down. We'll suggest a pilot line and what it would prove.
Tell us how the work runs today, which systems already hold the data, and what a useful first release would change. We use that to judge scope before anyone writes a proposal.
The form goes to a solutions architect at THE TISA. You get a direct reply on fit, approach, and what we would need from your team.
Share your scope
Tell us about the workflow or product. A solutions architect replies within one business day.