Sensors that talk. Machines that listen. Plants that learn.
Industrial IoT, MES, SCADA, OPC UA, MQTT, edge compute, digital twins — Industry 4.0 isn't a slide deck for us, it's the stack we build on. From a single sensor on a CNC mill to a unified namespace across an entire plant, we wire the physical world into software that actually runs the business.
Most factories already have sensors. Almost none of them have the data.
The gap between a sensor reading and a decision the business can act on is where most automation projects die. PLCs talk to other PLCs. SCADA shows the operator, not the CFO. Data sits in proprietary historians. We build the missing layer — OPC UA on the floor, MQTT to the cloud, MES in the middle — so every signal ends up where it needs to, in the form it needs to be in.
Every signal, every machine, every line — addressable from one place.
Five levels. One automation pyramid.
The classic ISA-95 / Purdue model — what every plant we touch looks like under the hood.
Where boardroom decisions live — KPIs, finance, supply-chain planning.
The plant brain. Schedules production, tracks orders, stores every signal.
Operator-facing dashboards. Where humans see what the machines are doing.
Real-time logic. Microsecond loops, deterministic control, safety interlocks.
The physical layer. Where atoms become bits — and bits become atoms again.
Every signal flows up. Every command flows down. We make sure both directions stay clean.
“Every minute of unplanned downtime costs a manufacturer real money.”
The average factory loses 800 hours a year to unplanned stops. The average factory with proper IIoT loses 200. The maths is straightforward.
Fourteen of them. Probably yours too.
Bridges between legacy fieldbuses and modern IIoT — without ripping out what works.
Got something exotic — DNP3, IEC 61850, GENI, BiSS-C? We've probably touched it. Send us your protocol stack and we'll come back with a bridge plan.
Plant floor, in one screen.
Sample dashboard. Yours mirrors your floor — same layout, your machines, your KPIs, your shifts.
Ten sectors, one operating system.
Same playbook. Different sensors, different compliance, different floor walks.
Manufacturing
Discrete + process plants — cell-level monitoring, OEE tracking, traceability.
Energy & utilities
Substations, solar farms, water treatment — remote SCADA + load balancing.
Oil & gas
Wellhead monitoring, pipeline flow, tank gauging — explosion-proof gear, IEC 61511.
Food & beverage
Recipe control, batch tracking, cold-chain monitoring, FSSAI / FDA compliance.
Automotive
Body shop robotics, paint-line PLCs, MES handshakes, traceability per VIN.
Pharma & life sciences
GxP-validated systems, batch genealogy, electronic signatures (21 CFR Part 11).
Smart buildings
BMS, lighting, HVAC, occupancy — BACnet over IP, energy dashboards.
Agriculture
Precision farming, irrigation, livestock telemetry, drone integration.
Logistics & warehousing
AGV / AMR fleets, conveyor sortation, RFID, WMS handshakes.
Mining & metals
Crusher monitoring, conveyor health, dispatch systems, predictive maintenance.
Twelve disciplines. All in-house.
Wiring on Monday. ML model on Friday. The same team owns both.
Sensor & instrumentation deployment
Pick the right transducer for the job. Install, wire, calibrate, document. Loop diagrams ready for audit.
PLC programming & integration
Siemens TIA Portal, Rockwell Studio 5000, Mitsubishi GX Works — ladder, structured text, function blocks.
SCADA / HMI development
Ignition, Wonderware, FactoryTalk, WinCC — operator screens that match how your team actually works.
MES integration
OEE, batch genealogy, scheduling, traceability — wired to your ERP via OPC UA or Sparkplug-B MQTT.
OPC UA & MQTT broker setup
Unified namespace, role-based access, certificates, redundancy. The connective tissue of your plant.
Edge compute & protocol gateways
Convert legacy fieldbuses, run inferencing on the edge, buffer when uplink fails. Sub-ms determinism.
Cloud analytics & dashboards
Stream telemetry to AWS / Azure / GCP. Time-series storage, real-time KPIs, executive views.
Predictive maintenance & ML
Vibration analytics, anomaly detection, failure prediction. Less wrench-time. Fewer unplanned stops.
Digital twin & simulation
Model the line in Unity / Omniverse, train operators, validate changes before the real floor sees them.
OT / IT cybersecurity
IEC 62443 segmentation, Purdue model zones, secure remote access, asset inventory, anomaly detection.
Compliance & standards
ISA-95, IEC 62443, GAMP 5, 21 CFR Part 11, FSSAI — depending on your sector. We document for audit.
Operator training & runbooks
Your team, on the system. Plus runbooks for incidents — so the right thing happens at 2 a.m.
“The plants that survive the next decade are the plants that listen to themselves.”
Industry 4.0 was a buzzword. Industry 5.0 is the bill coming due.
Real numbers. Not slide-deck numbers.
What customers we've worked with see in the first 6–12 months. Your mileage depends on starting point and discipline.
On lines we instrument and tune in the first six months.
Predictive maintenance + early fault detection.
Run-to-condition replaces calendar-based servicing.
Real-time consumption visibility, peak shaving.
Industry 4.0 was the rehearsal. 5.0 is the show.
Where the floor, the cloud, and the human meet — and what that means for the plants we're building right now.
Digital twins
A live, physics-accurate copy of your line. Test changes, train operators, predict outcomes — before the real machinery moves.
Edge AI / TinyML
Inference where the data is born. Sub-millisecond decisions, no cloud round-trip, vibration models running on the PLC itself.
5G factories
Wireless sub-ms control over private 5G. Mobile robots that roam, retool, and restream — without ethernet drops.
Autonomous mobile robots (AMRs)
Fleet-managed, SLAM-navigated, swap-attached. They map the floor, deliver kits, flex around humans.
Sustainability metrics
Per-product carbon, per-line energy, per-batch water. ESG reporting wired into the same OPC UA bus that runs the plant.
Industry 5.0 — humans + machines
Cobots that share workspace. Wearables that prevent injury. AI that augments operators instead of replacing them.
Industry 5.0 isn't a replacement for 4.0 — it's 4.0 with the human put back at the centre. The plant becomes a partner, not a process.
Audit, pilot, prove, then we scale.
Plant audit
Walk the floor, list assets, capture the as-is. Two weeks. Output: a written maturity assessment.
Pilot one line
Instrument a single line, prove the data, prove the dashboards. ROI on a single line in 90 days.
Validate ROI
OEE before / after. Downtime before / after. A real number to take to the board.
Scale plant-wide
Roll out to remaining lines. Standardise the unified namespace. Train operators in waves.
Operate & improve
On-call, monthly reviews, ML model retraining, security patching. We stay on the line.
We don't do automation theatre. We do automation that pays for itself inside the first quarter.
Got a line worth instrumenting?
Free plant audit. Pilot in 90 days.
Walk us through one production line. We'll come back with a maturity assessment, a proposed unified namespace, and an OEE projection — yours to keep.
FAQ