Shop-floor reality, visible from the office — without stopping a single line.
Production plans live in one system, actual output lives on a whiteboard, and quality lives in a register. We connect the floor to the office so plan, actual, and quality tell the same story in real time.
If that reads like your business, none of it is unusual — and none of it has to stay that way.
Every one of these is a symptom of information being captured more than once, or not captured at all.
No abstractions. For each task your team does today, here is what changes, and exactly which capability does the work.
Supervisors write production counts, downtime, and rejections on shift sheets. The sheets are typed into Excel the next morning, if someone has time.
Operators log output, downtime reason, and rejections on a rugged tablet or scanner at the machine. Data reaches the dashboard the moment it is entered.
How: Business Process Digitization — mobile capture with offline tolerance and validation at the point of entry.
The plan lives in the ERP and the actual lives on a whiteboard. Variance is discovered at a weekly review meeting.
Plan and actual sit side by side on a live board with variance highlighted per line and per shift. Slippage is visible within the hour it happens.
How: Integration between your ERP and a real-time production dashboard.
Inspectors fill a register by hand. Photographs of defects, if taken at all, sit on someone's phone.
Digital inspection forms with mandatory fields and attached photos, plus camera-based checks for defects, counts, and presence on high-volume lines.
How: Vision AI for automated inspection, with digitized inspection workflows for manual checks.
Downtime is recorded as a rough time and a vague cause. Nobody can say which cause costs the most across a quarter.
Every stoppage captured with a structured reason code, duration, and operator note — producing a ranked Pareto of what is genuinely costing you production time.
How: Structured capture plus automated analysis and reporting.
Maintenance happens when something breaks. Service schedules exist in a file that is rarely opened.
Maintenance jobs raised automatically from run-hours or calendar triggers, assigned to a technician, with spares checked against stock before the job is due.
How: AI and Intelligent Automation — trigger-based work order generation with stock validation.
Actual cost per job is calculated at month-end by combining several spreadsheets, long after any corrective action is possible.
Material, labour, machine time, and rejection cost accumulate against the job as it runs. Margin is visible while the job is still on the floor.
How: Custom platform integrated with your ERP for live cost accumulation.
Stores raise indents on paper. Purchase re-types them, then chases approvals by phone and WhatsApp.
Indents raised digitally with stock levels visible, routed for approval on a phone, converted to a PO, and tracked to receipt — with reorder alerts before stockout.
How: Business Process Digitization with rule-based approval routing and reorder triggers.
Accounts key each supplier invoice line by line, then match it manually against the PO and GRN.
Invoices read automatically including line items and GST details, then three-way matched against PO and GRN. Only mismatches reach a person.
How: Vision AI for invoice extraction with automated three-way matching.
Dispatch details are phoned through, and proof of delivery is a signed slip that may or may not come back.
Dispatch recorded against the order with photographs, e-way bill reference, and a driver-captured proof of delivery that attaches itself to the record automatically.
How: Photo-driven field workflows with Vision AI capture and auto-filing.
Customers phone to ask where their order is. Somebody walks to the floor to find out and calls back.
A customer portal shows live order status, and a Voice AI agent answers status calls instantly at any hour by reading the same live data.
How: Customer portal plus Voice AI grounded in your order system.
Indicative ranges from comparable programmes. Your assessment produces numbers for your own operations.
Each is a real, scoped piece of work — usually delivered one at a time, starting with whichever pays back fastest.
One screen showing every line: planned vs actual, current job, downtime, rejection rate, and shift progress. Visible in the office, the MD's phone, and on a floor display.
Digital inspection plans, mandatory field capture, defect photographs, non-conformance workflow, and CAPA tracking — with full traceability by batch.
Supplier invoices read automatically and three-way matched against purchase orders and goods receipts, with only genuine exceptions reaching your accounts team.
Defect detection, counting, and presence checks running continuously on high-volume lines, with images retained as evidence against customer complaints.
Keep the ERP you have. We build the integration layer so shop-floor systems, quality, maintenance, and dispatch read and write to it without manual re-entry.
We integrate rather than replace wherever it makes sense. These are the platforms we most commonly connect to in this sector.
When the workflow captures the work properly, the evidence an auditor asks for already exists.
Get the work out of registers, WhatsApp threads, and spreadsheets — and onto a system.
Stop reading invoices, checking documents, and inspecting by eye alone.
Move off rigid, expensive systems without stopping the business.
Hand the repetitive decisions to a system that never gets tired.
Built around how your business actually works — and maintainable afterwards.
Almost never. Manufacturing ERPs hold years of configuration and statutory history. We integrate with what you have and build the shop-floor and workflow layer around it.
The floor interface is designed for gloved hands and a shift environment: large targets, few taps, scanner input where possible, and no typing where a code will do. Where literacy varies, we use icons and regional language labels.
Capture is built offline-tolerant. Devices store entries locally and sync when connectivity returns, so a dead spot near the furnace does not stop production recording.
That is the recommended approach. One line or one process proves the value and reveals the practical issues at low cost, and the rollout to the rest of the plant is then much faster and cheaper.
A short discovery gives you a written picture of where time and money are leaking, and a phased plan to fix it. No obligation.