Manufacturing

Plant-floor visibility that feeds the office without a second set of numbers.

Line and machine monitoring, access-control and attendance data, and production reporting connected into one system, so supervisors, HR and management read the same record.

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Where the gap usually is

Factories run on devices that already produce data: PLCs, access-control terminals, scanners and line sensors. The problem is that each one reports into its own portal. We connect them into a single operational view with the reporting each team needs.

PLC vendor protocolsHikvision / access-control APIsModbusOPC UA.NET CoreSQL ServerAngular / web portals

What we build for Manufacturing

  • Line, machine and station monitoring with status, throughput and downtime reasons
  • Access-control and biometric device integration for attendance and site presence
  • Centralised reporting portals: adjustments, sign-offs, logs, users and permissions
  • PLC integration and HMI screens for new lines and retrofits
  • Maintenance and ERP sync on a governed schedule
  • Role-based dashboards for supervisors, HR and management

One operational system, five stages

The same connected-systems discipline we apply to revenue, applied to plants, stations, fleets and venues: every stage reads from the same data model.

  1. 01

    Capture

    Field I/O, historians, telematics and manual readings land in one data model.

  2. 02

    Monitor

    Live values, status and KPIs at plant, station and unit level.

  3. 03

    Alert

    Rules with duration, quality and cooldown route to the right person.

  4. 04

    Act

    Operators and engineers respond with context, on screen or on mobile.

  5. 05

    Report

    History, comparisons and audit trails for management and compliance.

The four capabilities behind it

SCADA & HMI systems

Supervisory control and operator screens for plants, stations and units: live values, alarms, trends and history in one place operators actually use.

  • Plant → station → unit hierarchy with status, KPIs and drill-down
  • Operator HMI screens designed for the control-room and the phone
  • Alarm management: thresholds, hysteresis, acknowledgement and audit trail
  • Trend, compare and replay for any signal over any window

PLC programming & integration

Controller logic, panel integration and commissioning that connects field I/O to the supervisory layer without vendor lock-in.

  • Ladder / structured-text logic for new lines and retrofits
  • Modbus, OPC UA, MQTT and vendor protocols bridged to one data model
  • Panel integration, I/O mapping and factory / site acceptance testing
  • Safe-state design, interlocks and documented change control

IIoT & remote monitoring dashboards

Sensors and telematics streamed to a secure cloud layer, then rendered as executive dashboards, mobile apps and personal alerts.

  • Device-to-cloud ingestion with buffering for unreliable links
  • Executive KPI dashboards: national, regional, asset and unit views
  • Personal alert rules with duration, quality and cooldown so noise stays low
  • Mobile apps (iOS and Android) for owners, engineers and field teams

OT / IT integration & data historians

Plant data connected to reporting, ERP and analytics through historians and read-only adapters, with the OT network kept isolated.

  • Historian (PI, SQL, time-series) read-only adapters and replication
  • Reporting, ERP and maintenance-system sync on a governed schedule
  • Role-based access, audit logs and data quality flags on every feed
  • Segmented architecture: no direct internet exposure of control networks

Related work

Delivered systems with the same data-to-decision pattern. Clients are not named.

.NET Core 3.1, Microsoft SQL Server, Angular 12

Centralised Attendance & Reporting Portal on Access-Control Device Data

A centralised management portal for a poultry production company that turns Hikvision access-control device data into attendance summaries, adjustment reports, sign-off requests and audit logs.

Read the case study →

Questions we get asked

Can you integrate the access-control devices we already have?

Yes. We have built centralised reporting on top of Hikvision access-control data, turning device logs into attendance, adjustment and sign-off workflows with an audit trail, without replacing the hardware.

Do we need new PLCs for line monitoring?

Rarely. Most line monitoring reads from the controllers you already run through their supported protocols. New PLC work is scoped only where logic must change or a line is being added.

Do you replace our existing SCADA or work with it?

Usually we work with it. Most projects integrate an existing SCADA or historian into a modern supervisory and reporting layer, and only replace components that are unsupported or unsafe. Replacement is a scoped decision, not a default.

How do you keep control networks secure when adding remote monitoring?

Control networks stay segmented. We read from historians or edge gateways through read-only adapters, publish to a separate cloud layer, and never expose PLCs or SCADA servers directly to the internet. Access is role-based and logged.

Can operators and executives use the same system?

Yes, with different views. Operators get HMI screens, alarms and trends; executives get regional and asset KPIs, history and personal alerts on mobile. Both read the same data model, so the numbers agree.

Which protocols and platforms do you integrate?

Modbus TCP/RTU, OPC UA, MQTT, common PLC vendor protocols, and historians such as PI and SQL-based time-series stores. Where a protocol is proprietary we work through the vendor's supported interface rather than reverse-engineering it.

Start with a discovery call

Fifteen minutes on what you run today, what is missing above it, and whether a build makes sense. No proposal until we have seen your system.

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Also for

Energy & UtilitiesOil, Gas & ProcessWater & WastewaterVenues, Retail & Events