Live overview and flow map
A live board of every machine’s state, alarms and part flow, plus a material-flow map with visit numbers and documented return legs, updated by push rather than by refresh.
MES · Manufacturing execution
Every machine on one board.
Every part, provable.
The factory’s operating system, proven on a small scope first. It shows what every machine is doing right now, tells each operator what to run next, and refuses to let a job start or a certificate be issued when the conditions for it are not met.
How it works
One bus up from the machines, three ways back down to people.
Every asset publishes through a small edge gateway onto one event bus. The MES governs what happens next: which operation may start, which record may be written, which certificate may be issued. What comes back out is three views of the same truth, an operator terminal at the machine, a live board for the floor, and an assistant you can ask why.
01 Machines publish through an edge gateway. Nothing on the floor talks to the cluster directly.
02 One bus, one namespace. Adding the thirtieth machine costs what the third did.
03 The board shows every asset, and flags the one that needs a person.
04 Ask the assistant why. It explains from the data and suggests. You decide.
Modules
Nine modules, one record.
Execution, quality, metrology and traceability are not separate systems that reconcile overnight. They write into the same ledger, under the same interlocks, in the same transaction.
Operator terminal
A machine-scoped touch terminal showing the dispatched operation and its work instruction, gating Start and Record behind refusing interlocks and an electronic signature.
Quality: FAI, NCR, MRB, CAPA
AS9102 first-article inspection with CMM auto-import, alongside the full non-conformance spine: NCR lifecycle with lot containment, MRB disposition with customer flow-down approval, and CAPA / 8D.
Metrology and SPC
The calibrated-asset register, Zeiss Calypso and Q-DAS measurement ingestion, and SPC control charts. This is the authority behind the question “is this gauge trustworthy right now?”
Genealogy and Certificate of Conformity
An append-only as-built ledger per serial number with heat and lot where-used traceability, ending in a gated, immutable certificate archived to write-once storage.
Telemetry and historian
High-frequency machine telemetry lands in a time-series store with live state, alarm history and shift timelines, then egresses to the plant’s long-term historian.
Alerting and notifications
A configurable trigger catalogue turning quality, calibration, certification and integration events into localized email and in-app alerts, with platform alerts relayed into the operations Microsoft Teams channel.
ERP and PLM integration
Anti-corruption adapters to ISAH ERP and Windchill PLM, each shipping with a simulator mode so the platform runs standalone before a single integration is live.
Identity and gateway
Microsoft Entra ID single sign-on, role- and permission-based access, and step-up MFA electronic signatures, all behind one API gateway that validates every call.
The event-driven factory
One data bus. No point-to-point wiring.
Most factories integrate machine by machine: every new controller means a new cable, a new script, a new screen. Adding the thirtieth machine should cost what adding the third did, and it does, because every machine publishes into the same namespace and nothing is integrated twice.
Most factories
Machine by machine
3 integrations per machine
Every consuming system needs its own cable to every machine. Four machines and three consumers is twelve separate integrations, each built and maintained on its own, and the fourth machine reused nothing the third had already solved.
How we build it
One event bus
1 integration per machine
A machine is integrated once, at the edge, and publishes into one broker. Everything above it subscribes to a namespace rather than to a machine, so the same four machines cost four integrations and adding the thirtieth touches nothing above the broker.
Inside the bus
Four layers, and what each one is for.
The right-hand architecture above, taken apart. Read it the way a machine’s data travels: it meets the edge, the edge publishes to the broker, the namespace organises what is on it, and the stores keep what has to outlast the shift.
Translate
Edge gateways convert proprietary controller and metrology protocols into one common event format, close to the machine, with local buffering and filtering. Machines never reach the cluster directly.
OPC UA · MTConnect · Calypso / Q-DAS
Transmit
The broker is the integration boundary. Producers and consumers depend on the broker contract, not on each other, which keeps machines, MES and analytics decoupled.
MQTT (Mosquitto) · RabbitMQ
Organise
One stable, hierarchical view of plant state on an ISA-95 topic tree, in a plain-JSON envelope that stays deliberately human-readable, because AS9100 auditors read it.
aero/sibiu/{area}/{cell}/{machine}/{metric}
Collect
Telemetry lands in a time-series store; relational and document stores hold only derived, aggregated and transactional data. Keeping the firehose off the database is what lets this scale factory-wide.
Time-series · PostgreSQL · WORM archive
The benchmark
Built to produce evidence, not just data.
We built against AS9100D, AS9102 and NADCAP because it is the most demanding evidence regime we could find, not because the system only works in aerospace. Certification belongs to your quality system, not to software, and we will never claim otherwise.
AS9100D
The aerospace quality system is the default throughout, not a lowest common denominator.
AS9102
First article inspection, with measurement results imported from the CMM rather than retyped.
NADCAP
Accreditation scope is enforced as an interlock before the process runs, not filed as a note.
EN 10204 3.1
Material certificates are carried through the genealogy record of every serial number.
Electronic signature
Step-up MFA through Entra Conditional Access. The signature manifest is rendered verbatim.
Retention
10 to 40 years per customer flow-down. Certificates of conformance 40 years, write-once.
IEC 62443
Edge gateways publish northbound only. Nothing on the platform connects inbound to the edge.
Export control
Marked records need an authorization claim. Denials are audit logged and links are single use.
Rollout
Prove it on two machines. Then scale it across the factory.
Adoption is deliberately narrow at the start. Prove the pattern on two real machines and a simulated fleet, and every machine after them costs about a day.
- Stage one
The pilot
Two live machines, a machining centre and a coordinate measuring machine, prove every layer with real data. Simulated assets alongside them prove the scale, so a procurement lead time never blocks the work.
- One controller type, one measurement device
- One routing, end to end
- Live board, operator terminal and quality spine
- Simulated fleet for scale testing
- Stage two
The other controller types
One real machine per remaining controller family: Fanuc, Okuma, MTConnect, Siemens. Each needs one adapter, written once, at roughly two to four weeks per type.
- Stage three
The whole factory
Every remaining machine of a type already proven. No new software: a registry entry and a maintenance slot, at roughly half a day per machine.