Manufacturing Software Development

Custom manufacturing software ranges from $150k to $400k depending on scope. Basic MES connecting 5-10 machines with production tracking starts around $150k-$200k. Comprehensive systems integrating ERP, quality management, and predictive maintenance run $250k-$400k. Often less than off-the-shelf ERP implementations requiring extensive customization. We provide fixed-price proposals after assessing requirements. Most manufacturers achieve ROI within 12-18 months through downtime reduction, labor savings, improved efficiency. Key difference: you pay for exactly what you need, not unused features.

Manufacturing systems typically deploy in 8-16 weeks with phased rollouts. Single production line MES goes live in 8-10 weeks. Multi-line systems with quality integration take 12-16 weeks. Comprehensive ERP replacements run 16-24 weeks for initial modules. We use phased approaches: pilot on one line, prove value, then expand. This beats the 6-18 month implementations typical with off-the-shelf platforms requiring extensive configuration. Implementations are faster because we build exactly what you need, not configure generic platforms.

Yes. We've connected machines from the 1980s and 90s that manufacturers thought couldn't share data. We work with all industrial protocols: Modbus RTU/TCP, OPC-UA, Profinet, EtherNet/IP, BACnet, proprietary protocols. For equipment with no network capability, we add IoT sensors and edge devices. One client had 35 legacy machines with no connectivity—we implemented protocol adapters and edge gateways, providing real-time OEE monitoring for the first time. We handle industrial networking complexity for reliable data collection regardless of equipment age.

ERP manages business operations: financials, planning, purchasing, sales orders, inventory at high level. MES manages shop floor execution: what's being produced right now, on which machines, by which operators, with real-time quality and efficiency tracking. ERP plans what should happen, MES ensures it happens correctly and tracks actual performance. Most manufacturers need both, integrated. ERP schedules production and manages materials. MES executes plans on shop floor and reports results back. We build systems where both communicate seamlessly—production actuals flow to job costing, material consumption updates inventory, quality data links to customer orders.

We implement defense-in-depth security: network segmentation isolating shop floor from business systems, encrypted data transmission, role-based access control, audit logging of all activities. For Industrial IoT, edge computing keeps critical data on-premises with optional cloud sync. We follow IEC 62443 industrial security standards and can deploy entirely on-premises if required. Manufacturing environments have unique challenges—equipment that can't be patched, legacy protocols without encryption, 24/7 operations intolerant of security-induced downtime. Our architecture accounts for these constraints while maintaining security. We've secured systems for aerospace manufacturers with ITAR requirements and medical device companies with FDA regulations.

Yes, we design for scalability from day one. Start with one production line, prove ROI, then expand plant-wide. Architecture supports adding machines, lines, entire facilities without rebuilding. One automotive supplier started with 10 machines in 2020, now has 45 machines across 2 facilities on same platform. No per-user licensing means adding operators doesn't increase costs. Database and application architecture handle enterprise-scale data volumes—we've built systems tracking millions of production events daily. Cloud infrastructure scales automatically during peak loads. Modular design lets you add capabilities over time without disrupting existing operations.

We provide hands-on training during implementation, typically 3-5 days on-site working directly with operators, supervisors, maintenance teams. Training covers daily operations, common scenarios, troubleshooting. We create custom documentation and video guides specific to your workflows. Post-launch support includes direct access to developers who built your system—no tiered support queues. Response times measured in hours, not days. We provide 3-6 months intensive post-launch support while system stabilizes. After that, monthly support packages cover bug fixes, minor enhancements, help desk. Many clients bring development in-house over time—we facilitate transition with knowledge transfer.

Yes, we regularly integrate custom manufacturing systems with major ERP platforms including SAP S/4HANA, Microsoft Dynamics 365, Oracle NetSuite, Infor, Epicor. We build bidirectional interfaces: production schedules flow from ERP to shop floor, actual production and material consumption flow back to ERP for job costing and inventory updates. Integration handles master data synchronization—BOMs, routings, work centers—and transactional data like production confirmations, quality results. We use modern APIs where available and work with older methods (IDocs, flat files, database connections) when necessary. Goal: ERP and shop floor systems work as one cohesive platform.

We start with critical equipment having highest downtime impact, typically 3-5 machines for pilot. Install IoT sensors capturing vibration, temperature, power consumption, operational parameters. Collect baseline data for 4-8 weeks to understand normal operation. Machine learning models learn failure signatures—patterns that precede breakdowns. System alerts maintenance teams 2-4 weeks before predicted failures, specifying likely failure modes. Integrate with CMMS to generate work orders automatically. One packaging line reduced unplanned downtime by 68% within 6 months catching motor, bearing, gearbox issues before catastrophic failures. After proving ROI on pilot equipment, expand to additional machines. System learns continuously, improving predictions over time.

For regulated industries—aerospace (AS9100), medical devices (ISO 13485, FDA 21 CFR Part 11), automotive (IATF 16949)—we build compliance into system architecture. This includes electronic signatures with audit trails, revision-controlled documentation, automated validation protocols, traceability from raw materials through finished goods. We implement validation workflows matching quality system requirements. For FDA-regulated manufacturers, we follow Part 11 guidelines for electronic records and signatures. System maintains complete audit trails: who changed what, when, why. Quality documentation generation automated, reducing compliance labor while improving accuracy. We've supported clients through FDA, EASA, AS9100 audits with zero findings related to software systems we built.