Data Acquisition
01Connects to your existing PLCs and control systems over OPC (via Kepware or equivalent), and to your lab and ERP systems, without requiring new field instrumentation.
Production Analytics for Manufacturing
Production Analytics Software for Real-Time Manufacturing Insights
We build production analytics software that turns scattered plant-floor data — PLC tags, delay logs, lab results, SAP records — into one live view of what is actually happening on your production floor, heat by heat, batch by batch, shift by shift. This is a manufacturing analytics platform built for plants where a delay nobody sees until the shift-end report is a delay that already cost you money.
PLC TagsDelay LogsLab AnalysisSAP ERP
Live Status
Active
The Environment Problem
Production Data That Arrives Too Late to Act On
Most production floors do not lack data. A steel melting shop alone generates PLC tags from every furnace, ladle furnace, vacuum degasser, and caster; delay codes logged by operators; lab analysis results; and transaction records pushed to SAP. The problem is where that data lives and when it becomes visible.
Furnace & Equipment Delays: A furnace delay caused by a crane issue, a refractory problem, or a planned shutdown running long is recorded on a paper log or a local screen — and only shows up in a report the next morning
Lagging Consumption Calculations: Energy and material consumption per ton is calculated after the fact in a spreadsheet, not visible while the heat is still in progress
Disconnected Operational Systems: Production and delay data live in disconnected systems: PLCs on the floor, a local HMI at each station, and SAP records that reconcile days later
Meeting-Room Retrospectives: Supervisors and plant managers see yesterday's numbers in a meeting, not today's numbers while there is still time to act
Scattered Root-Cause Data: When something needs root-cause investigation — "why did we lose four hours this week" — the answer is scattered across shift logs from four different stations, not summarized anywhere
None of this is a shortage of data. It is a shortage of a system that makes that data usable in real time, by the people making decisions on the floor.
Software
What Is Production Analytics Software?
Production analytics software continuously pulls data from your existing PLCs, SCADA, lab systems, and ERP, and turns it into a single, real-time operational picture: what is running, what is delayed, why, and what it is costing. Unlike a static end-of-shift report, a production analytics platform updates as the process happens — so a delay, a quality deviation, or an energy spike is visible to the people who can respond to it while it is still happening, not the next morning.
It also differs from a plain SCADA screen. SCADA shows you the current state of a single station. A production analytics platform aggregates that data across every station in a production line — furnace, refining, casting, and beyond — into one dashboard that shows the whole process, not one piece of it at a time.
How it works
How Our Production Analytics Platform Works
We connect existing PLCs, control systems, lab, and ERP data into a central database and live operational picture — delivering complete, real-time visibility without requiring new field instrumentation.
Unified Production Model
02Structures heat, batch, or shift-level data — including delays, material consumption, and quality results — into a central database (typically PostgreSQL) that becomes the single source of truth for production reporting.
Real-Time Dashboards
03Presents live, role-based dashboards in a browser: operators see station-level status, supervisors see cross-station delay and throughput data, and plant managers see cost and productivity summaries — no client software install required.
Delay and Loss Attribution
04Every stoppage is logged against a defined delay catalogue and responsible agency (for example: Operations, Maintenance, Planned Shutdown, Refractory, Crane, Electrical, External), so "we lost time" becomes "we lost 297 minutes this month to crane availability."
Integration and Reporting
05Confirmed production and delay data flows back to SAP or your ERP of record, with scheduled report emails and full historical trend data for continuous improvement.
Real-Time Visibility
What You Can See in Real Time
Live Production & Batch Count
Live production and heat/batch count, updated as each unit completes — not reconstructed after shift-end.
Categorized Delay Attribution
Delay time broken down by responsible agency and cause, so recurring bottlenecks (a specific crane, a specific maintenance category) are visible as patterns, not one-off incidents.
Continuous Consumption Tracking
Energy and material consumption per ton or per unit produced, tracked continuously rather than calculated in a spreadsheet days later.
Process-Time Distribution
How many heats or batches ran within target time versus how many ran long, and by how much.
Role-Based Dashboards
An operator's screen, a metallurgist's or quality engineer's screen, and a plant manager's summary view are different by design, each showing what that role actually needs.
Automated Scheduled Reports
Plant managers get a daily or weekly summary without building it by hand.
Full Historical Trend Data
A recurring issue can be traced back across weeks or months, not just the current shift.
Live Deployment
Inside a Live Deployment
At the steel melting shop of a leading integrated steel plant, production across the Electrical Arc Furnace, Ladle Furnace, Vacuum Degasser, and billet caster stations used to live in separate systems: PLC data at each station, delay information logged locally, and consumption figures reconciled against SAP after the fact. There was no single live view of what was happening across the shop at any given moment.
We deployed a Level-2 production system that pulls live data from every station over OPC, tracks each heat from furnace to caster, and surfaces it in a real-time web dashboard — accessible over the network without installing any client software, to any user with the right login. The dashboard shows, at a glance: total heat count for the month and shift, average arching time, total oxygen consumption, and preparation delay for the period — alongside a breakdown of delay time by responsible agency, so it is immediately clear whether this month's losses are concentrated in maintenance, crane availability, refractory issues, or something else entirely. Energy and material consumption are tracked per charged ton, continuously, instead of being calculated after the heat is finished.
Confirmed production data is pushed automatically to SAP through a dedicated integration layer, so the plant's production analytics and its ERP system stay in sync without manual reconciliation.
Outcomes
Business Impact
1
Increased productivity
reduced cycle times and less unplanned downtime, because delays are visible and attributable while they are happening, not after
2
Enhanced quality
real-time monitoring of critical process parameters supports consistent output that meets specification, instead of finding out about a deviation after the batch is finished
3
Data-driven decision-making
plant managers and process engineers get insights based on live production data, not a reconstructed report
4
Cost savings
visibility into where time and material are actually being lost turns "we think we're losing efficiency somewhere" into a specific, addressable number
5
Integrated operations
every station in the production line reports into one system, instead of operating as a disconnected island
6
Traceability and compliance
every heat, batch, and delay is logged and auditable, supporting both internal process improvement and external compliance review
Industries
Industries We Serve
Production analytics delivers the most value in industries where a production process runs continuously across multiple stations and a delay or deviation at any one of them affects the whole line.
01
Steel
furnace, refining, and casting operations
02
Power & Process Industries
continuous monitoring and delay tracking
03
Cement & Heavy Manufacturing
multi-station line tracking and energy/material analytics
If your plant already has PLC/SCADA automation and an ERP system like SAP, our production analytics layer connects to what you have rather than requiring you to start over.
FAQ
Frequently Asked Questions
Production analytics software continuously pulls data from your PLCs, SCADA, lab systems, and ERP, and turns it into a real-time view of what is running, what is delayed, why, and what it is costing — instead of a static report assembled after the fact.
CTA
See Your Production Floor in Real Time
If your plant managers are still finding out about yesterday's bottlenecks in this morning's meeting, we can show you what a live production analytics deployment looks like.