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Manufacturing & Industrial

Where IoT Meets Operational Efficiency and Data Drives Decisions

Modern manufacturing is data-driven — sensors on machines, analytics on production lines, predictive maintenance that prevents downtime. Our team has bridged IT/OT systems, integrated IoT devices at scale, built real-time monitoring dashboards, and created systems that turn machine data into operational insights.

IoT Integration
Predictive Maintenance
Real-Time Monitoring
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20+
Systems Built
99.9%
Uptime
5+
Years Experience
14
Specialists

What We've Built:

IoT PlatformsPredictive MaintenanceSCADA IntegrationProduction MonitoringQuality ControlMES Systems
The Challenge

Manufacturing Complexity Requires
IT/OT Integration Expertise

IoT at Scale Is an Engineering Problem

Connecting one sensor is easy. Connecting 10,000 sensors across multiple plants with reliable data delivery, edge processing, and cloud integration — that's an engineering challenge. Most IoT projects fail because they underestimate infrastructure complexity.

Downtime Costs More Than You Think

Unplanned downtime in manufacturing costs $50K+ per hour on average. Predictive maintenance can reduce unplanned downtime by 50%. But predictive maintenance requires reliable data pipelines, ML models, and integration with maintenance workflows.

IT and OT Don't Speak the Same Language

Your IT team knows cloud and APIs. Your OT team knows PLCs and SCADA. Getting these systems to work together — securely, reliably, in real-time — requires engineers who understand both worlds.

"In manufacturing, the gap between IT and OT isn't just technical — it's cultural. We bridge that gap by speaking both languages: cloud-native architecture and industrial protocols. Our team has built systems that connect shop floor to top floor."
— Gautam Thapa, CEO
Manufacturing Capabilities

Manufacturing Systems Our Team Has Built

Deep experience across IoT platforms, predictive maintenance, production monitoring, and quality systems.

IoT & Sensor Integration

Connect everything, reliably

Industrial IoT at scale requires more than connecting devices — it requires edge processing, reliable data delivery, device management, and security. We build IoT platforms that handle thousands of sensors with industrial-grade reliability.

What We Deliver

  • Multi-protocol device connectivity (MQTT, OPC-UA, Modbus)
  • Edge computing for local processing
  • Time-series data ingestion at scale
  • Device management and firmware updates
  • Secure communication with TLS/certificate management

Technical Approach

Edge gateways, message brokers, time-series databases (InfluxDB, TimescaleDB), cloud IoT platforms (AWS IoT, Azure IoT).

Predictive Maintenance

Fix it before it breaks

Predictive maintenance uses sensor data and machine learning to predict equipment failures before they happen. We build systems that analyze vibration, temperature, power consumption, and other signals to identify issues early — reducing unplanned downtime and maintenance costs.

What We Deliver

  • Sensor data collection and normalization
  • Anomaly detection algorithms
  • Failure prediction models
  • Maintenance workflow integration
  • Alert and notification systems

Technical Approach

Time-series analysis, ML models (isolation forests, LSTM), integration with CMMS systems, configurable alerting thresholds.

Production Monitoring & MES

See your factory in real-time

Real-time visibility into production — OEE, cycle times, quality metrics, bottlenecks. We build monitoring dashboards and MES integrations that give operations teams the data they need to optimize production and identify issues immediately. Our systems have helped manufacturers improve OEE by 10-25% through better visibility and faster issue resolution.

What We Deliver

  • Real-time OEE dashboards
  • Production tracking and genealogy
  • Labor tracking and productivity
  • Quality control integration
  • Downtime tracking and analysis
  • Shift reports and KPI monitoring

Technical Approach

Integration with PLCs and SCADA, real-time event processing, time-series visualization, mobile-friendly dashboards.

Quality Control & Traceability

Track every part, every step

Quality systems that track materials, processes, and products through the entire manufacturing lifecycle. We build traceability solutions that support compliance, recall management, and continuous improvement — from raw materials to finished goods.

What We Deliver

  • Lot and serial number tracking
  • Inspection and test data capture
  • SPC (Statistical Process Control)
  • Certificate of Analysis generation
  • Recall management capabilities

Technical Approach

Barcode/RFID integration, genealogy data models, integration with ERP and QMS systems, compliance reporting.

IoT Architecture

Four-Layer IoT Architecture for Manufacturing

Industrial IoT isn't just about connecting sensors — it's about building a reliable, scalable architecture from edge to cloud.

Edge

Purpose: Local processing, protocol translation

Technologies: Edge gateways, OPC-UA servers, local databases

Connectivity

Purpose: Reliable data delivery

Technologies: MQTT, AMQP, industrial firewalls, DMZ architecture

Platform

Purpose: Data ingestion, storage, processing

Technologies: AWS IoT, Azure IoT, time-series databases

Application

Purpose: Dashboards, analytics, ML

Technologies: Custom applications, BI tools, ML pipelines

Key Principle: Edge-First Architecture

Don't send everything to the cloud. Process data at the edge when possible — reduces latency, bandwidth, and cloud costs. The cloud is for aggregation, long-term storage, and ML training. The edge is for real-time processing and control.

Technology Stack

Manufacturing Technology Stack

We choose technologies based on industrial reliability, integration capabilities, and long-term support.

IoT Platforms

AWS IoTAzure IoTCustom

Why: Industrial features, scale, flexibility

Edge

IgnitionKEPServerEXCustom

Why: OPC-UA, protocol translation

Databases

InfluxDBTimescaleDBPostgreSQL

Why: Time-series, transactions

Messaging

MQTTKafkaRabbitMQ

Why: Reliable delivery, buffering

Visualization

GrafanaCustom dashboards

Why: Real-time, flexible

ML/Analytics

PythonTensorFlowAzure ML

Why: Predictive models

Manufacturing tech stacks prioritize reliability and integration — systems must work with industrial protocols (OPC-UA, Modbus), handle time-series data at scale, and maintain uptime in production environments. Every technology choice considers operational resilience.

Integration Standards

Manufacturing Integrations We Handle

Manufacturing systems must integrate with SCADA, PLCs, MES, ERP, and CMMS platforms. We've built these connections.

Protocols

OPC-UAOPC-DAModbus TCP/RTUMQTTEtherNet/IP

SCADA Systems

IgnitionWonderwareFactoryTalkWinCC

PLCs

Allen-BradleySiemensMitsubishiBeckhoff

MES Systems

SAP MESRockwell FTPCAVEVACustom

ERP Systems

SAP S/4HANAOracleMicrosoft Dynamics

CMMS

SAP PMMaximoFiixUpKeep

Manufacturing integration is complex — legacy systems with proprietary protocols, intermittent connectivity, security boundaries between IT and OT. We've debugged OPC-UA servers at 3 AM and know where these integrations break in production.

Why Choose Us

Why ByteForever for Manufacturing?

IoT at Scale Experience

We've built IoT platforms handling thousands of sensors. Not proof-of-concepts — production systems with industrial reliability requirements.

IT/OT Bridging Skills

We understand both worlds: cloud architecture and industrial protocols. Our team can talk to your IT department and your plant engineers.

Predictive Maintenance Expertise

We've implemented predictive maintenance systems with real ML models — not just dashboards with thresholds. Actual anomaly detection that catches problems early.

Senior Industrial Engineers

5+ years experience each. Engineers who've worked with SCADA, PLCs, and MES systems in real manufacturing environments.

Money-Back Guarantee

If our first sprint doesn't meet your expectations, you don't pay for it. For manufacturing projects, we define success criteria upfront — IoT connectivity verified, data pipelines tested, integration endpoints validated. If we miss them, it's on us.

Related Services

Manufacturing Services We Offer

Custom Software Development

IoT platforms, MES, production monitoring

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AI Agents & Automation

Predictive maintenance, quality analytics

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Enterprise Modernization

Legacy system integration, SCADA modernization

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Frequently Asked Questions

Common questions about building manufacturing software.

Yes. We have experience with major SCADA platforms and PLC manufacturers. We typically use OPC-UA or native protocols to extract data without disrupting existing control systems.
Get Started

Ready to Build Manufacturing Systems That Connect, Monitor, and Predict?

Let's discuss your IoT integration, predictive maintenance, or production monitoring needs. Free 30-minute strategy call — we'll review your IT/OT requirements, sensor infrastructure, and whether we're the right fit.

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Or email directly: hello@byteforever.com