Your machines already know what happened on the last shift. Your team finds out tomorrow.
For plants running on Tally or SAP Business One, Excel, WhatsApp groups and paper checklists. We connect what you already have, automate the work that eats your supervisors' day, and keep it running after go-live.
Sound familiar?
Most plants we talk to run on the same handful of tools. Each one does its job. None of them talk to each other.
| What you use | What it's used for | Where it breaks |
|---|---|---|
| Tally Prime or SAP Business One | What it's used forAccounts, purchase, inventory, dispatch | Where it breaksProduction and scrap get entered at day end, if at all. Stock in the system doesn't match stock on the floor. |
| Excel | What it's used forProduction plan, daily production report, OEE sheet, rejection register | Where it breaksOne person owns the file. Five versions go around on email. Numbers are a day old by the time anyone reads them. |
| WhatsApp groups | What it's used forShift handover, breakdown alerts, photos of rejected parts | Where it breaksNothing is tracked to closure. When a customer complaint comes in, nobody can find who said what. |
| PLCs and CNC controllers (Siemens, Fanuc, Mitsubishi) | What it's used forRunning the machines | Where it breaksRun time, stop time, alarms and cycle counts sit inside the controller. Nobody reads them. |
| Paper | What it's used forQuality checklists, first-piece approval, machine logbooks, maintenance register | Where it breaksFilled at the end of the shift. Filed. Pulled out only for an audit or a complaint. |
| Email and paper files | What it's used forPOs, GRNs, supplier invoices, material test certificates | Where it breaksMatched by hand in stores and accounts. Mismatches get found late. |
Downtime reasons are guesses, OEE is an estimate, and tracing a rejected lot takes days.
Before AI: get the plant ready
Most AI and IoT projects in plants fail because the data underneath isn't ready. So we start there.
Plant data audit.
We walk the floor and map every source: which machines can give data and how, what lives in Tally or SAP B1, which Excel files people actually rely on, and what is still on paper.
Connect the machines.
Newer Siemens, Fanuc and Mitsubishi controllers can be read over OPC-UA, Modbus or the controller's own protocol through a gateway. Older machines with no data port get add-on sensors for run and stop status.
Make the records agree.
A machine stops at 10:15. The operator logs a reason at 10:23. Maintenance closes it at 11:05. That's three entries in three places for one breakdown. We join them into one downtime event with a start, an end, a reason and a production impact.
Start small enough to run.
The first phase is on-premise, lightweight and built on open-source tools, so your IT team can operate it. You add scale and paid components later, when real usage shows where they pay off.
- 10:15Stop signalMachine controller
- 10:23Reason loggedOperator
- 11:05Breakdown closedMaintenance
Downtime event
- Start
- 10:15
- End
- 11:05
- Reason
- From the operator, 10:23
- Production impact
- 50 min of planned output
What you get: a map of your plant's data, machines connected, one reliable record of production, downtime and quality, and a phased roadmap. This is a standalone engagement. You can stop here and still have something useful.
During AI: build what saves hours on the floor
Each of these is a workflow we build on top of the connected data. Most plants start with one or two.
Live production and downtime board
Today
The daily production report is an Excel sheet built from memory and WhatsApp messages. Downtime reasons get filled in later.
What we build
A live board per line and machine showing output against plan, running and stopped time, and downtime reasons captured at the machine on a phone or tablet. Shift summaries go out automatically, including to the WhatsApp group if that's where your team lives.
What changes
The plant head sees the current shift, not yesterday's. OEE is calculated from machine data instead of estimated.
Maintenance alerts and breakdown tracking
Today
Maintenance starts when someone calls. The machine logbook is paper. Repeat failures aren't visible.
What we build
Alarms and abnormal patterns from PLC data routed to the maintenance team. Breakdowns logged from a phone and tracked until closed. A searchable history per machine.
What changes
Fewer surprise stoppages, maintenance planned around how machines actually run, and a clear owner for every open breakdown.
Digital quality checks and approvals
Today
Paper checklists, first-piece approval waiting for a signature, rejections recorded in a register.
What we build
Checklists on a tablet at the machine, first-piece and deviation approvals on a phone, rejections logged with photos and escalated automatically. Where inspection is repetitive and visual, we add a camera-based check.
What changes
The line doesn't wait for signatures, and every quality decision is traceable when an auditor or customer asks.
Component and lot tracking
Today
Where a part is in the process is known only by walking the floor or asking the supervisor.
What we build
Tracking of parts or bins through each process step using barcodes or RFID, linked to the work order.
What changes
You know where every lot is and which steps it has passed. Tracing a rejected lot takes minutes.
Shop-floor assistant
Today
Operators call the supervisor for SOPs, settings and troubleshooting. Knowledge sits with two or three senior people.
What we build
An assistant on the phone, built on our ANT platform, that answers from your SOPs, work instructions, machine manuals and past breakdown records.
ANTWhat changes
New operators get answers without waiting, and what your senior people know gets written down.
Purchase and stores document flow
Today
Stores and accounts match POs, GRNs, supplier invoices and test certificates by hand before entering them in Tally or SAP B1.
What we build
An agent that reads the documents, matches them, posts clean entries to your ERP and sends only the mismatches to a person.
What changes
Less typing in stores and accounts, and mismatches caught at receipt instead of at payment.
After AI: keep it running
A plant system that nobody looks after stops being trusted within a few months. A gateway drops, a new machine gets added, a part changes and the camera check starts flagging good parts. We stay on after go-live.
Monitor the data connections, dashboards and agents, and fix them when something drops
Add new machines and lines as you grow
Tune alert thresholds and retrain camera checks when parts or processes change
Keep an audit trail of quality decisions and approvals for customer and IATF audits
A monthly review with the plant head on what's being used, what isn't, and what to do next
Runs as a monthly retainer.
Operations & GovernanceTried something that didn't stick?
Maybe it was an IoT dashboard nobody opens, or a vision pilot that worked in the demo and never went on the line. We look at what was built, tell you what's missing and what it would take to finish, and say plainly if it isn't worth continuing.
How we start
You don't have to commit to a big project. Each step earns the next one.
TalkFree
One conversation about your plant and your biggest blind spot. If we're not the right fit, we'll say so.
DiagnosePaid
A plant walkthrough and data audit. You get a map of your machines, systems and records, and a shortlist of where automation will pay back first.
Prove
One line, one use case, real numbers from your own floor.
Transform
Roll out across lines, connected into Tally, SAP B1 and the tools your team already uses.
Improve
We run, tune and extend it with you every month.
The people who walk your floor are the people who build the system. Senior engineers only, across machines, data, software and AI.
What's the one thing you wish you knew about your plant right now?
Tell us, and we'll tell you honestly whether it can be fixed and what it would take.