[ Factories rarely lack data. They lack data that arrives fast enough and in one place ]
Factories rarely lack data. They lack data that arrives fast enough and in one place — machine counts in a PLC, quality results on paper, production plans in a spreadsheet, and an ERP that learns what happened a day late. Techtaru Digital is a manufacturing software development company that closes that gap, delivering custom manufacturing software development across MES, production planning, predictive maintenance and manufacturing analytics built to run on a real shop floor.
Factories rarely lack data. They lack data that arrives fast enough and in one place — machine counts in a PLC, quality results on paper, production plans in a spreadsheet, and an ERP that learns what happened a day late. Techtaru Digital is a manufacturing software development company that closes that gap, delivering custom manufacturing software development across MES, production planning, predictive maintenance and manufacturing analytics built to run on a real shop floor.
Tell us which line loses the most hours and we will scope a pilot around itsystems designed around your routings, cells and constraints rather than a packaged template.
connected shop floor, real-time visibility and closed-loop improvement.
PLC, SCADA and sensor integration through edge gateways.
modules and interfaces around SAP, Dynamics, Oracle, Odoo or Tally.
assessment, ISA-95 data model design, pilot definition and business case.
SLA-backed support with defined response times, because downtime is measured in units.
Work orders and routings, operator terminals, material consumption, batch and serial traceability, genealogy, and electronic work instructions. MES software development is where paper and spreadsheets finally leave the floor.
Finite capacity scheduling, changeover and sequence optimisation, material availability checks, and what-if re-planning when a machine goes down.
OEE tracking, downtime reason capture at the machine, shift performance, and plant-to-plant benchmarking.
Condition monitoring from vibration, temperature and current sensors, anomaly detection, remaining-useful-life estimation and automatic work order generation.
In-process inspection plans, SPC charts with control limits, non-conformance reports, CAPA workflows, gauge calibration and supplier quality.
Asset register and hierarchy, preventive maintenance calendars, spares and criticality, MTBF and MTTR reporting.
Supplier portals, inbound scheduling and dock slots, vendor-managed inventory, ASN handling and supplier performance scorecards.
Engineering change control, revision sync to production, BOM alignment between design and manufacturing.
Yield and scrap analysis, energy per unit, defect image classification, cost per part and demand-driven planning support.
you cannot design an operator terminal from a video call. We document machine interfaces, data availability, existing systems and the metrics leadership reviews.
asset hierarchy, event model, edge architecture, ERP boundary.
OEE baseline captured before go-live so improvement is provable.
the capture screens are tuned with the people using them, on shift.
standard core with plant-level configuration where processes genuinely differ.
Connectivity: OPC UA, Modbus, MQTT Sparkplug B, edge gateways with local buffering. Backend: .NET, Java, Node.js, Python. Data: PostgreSQL, TimescaleDB or InfluxDB for machine telemetry, Kafka for event streaming, ClickHouse for analytics. Frontend: React with operator-optimised touch interfaces. Integration: SAP, Dynamics 365, Oracle, Odoo, Tally, PLM systems. Cloud and edge: Azure IoT, AWS IoT Greengrass, or on-premise deployment where plant policy requires it. Reference model: ISA-95 hierarchy from sensors through MES to ERP.
Shop-floor integration follows different rules. Operational technology networks prioritise availability and determinism over patch cadence, and a plant engineer will not let you install an agent on a running PLC. The standard bridge is OPC UA for machine data, MQTT for lightweight telemetry, and an edge gateway that buffers locally so a WAN outage does not stop production reporting.
OEE is where value is proven. Overall Equipment Effectiveness multiplies availability, performance and quality. Its usefulness depends entirely on honest downtime capture: if an operator cannot log a reason in under five seconds on a gloved touchscreen, the data will be fiction. We design capture UI around that constraint, because a beautiful analytics layer over invented downtime codes is worse than nothing.
Traceability is increasingly regulatory. Automotive suppliers work to IATF 16949, medical device manufacturers to ISO 13485 and FDA 21 CFR Part 11 for electronic records and signatures, and food producers to HACCP and FSSAI requirements. Each turns "nice traceability" into an audit obligation with specific evidence requirements.
Start with one line, not the whole plant. Manufacturing programmes that succeed prove value on a single line or cell, establish the data model, then replicate. The ones that stall try to digitise everything at once.
Fixed-scope pilots; dedicated squads for multi-plant rollouts; support retainers with defined response times for production-critical systems. Outbound movement is handled by our distribution and transport systems.
Indicative cost: a single-line OEE and downtime pilot typically starts around $20,000–$40,000. MES and multi-plant programmes are larger and best funded in phases tied to measured improvement. Timelines: OEE pilot on one line, 8–10 weeks; MES core, 5–9 months; multi-plant rollout phased over a year or more.
The manufacturing software development companies worth your time will ask to see the line before quoting. Tell us which line loses the most hours and we will scope a pilot around it.
Usually yes. ERP plans and records at order level; MES executes and records at operation level in real time. Running shop-floor execution from ERP alone is how plants end up with shadow spreadsheets.
Let’s talk about your manufacturing project. No obligation, just a conversation.
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