Does This Sound Familiar?
Every one of these is a solvable process and technology problem — not a “we need more staff” problem. Here's what our clients face before they come to us:
Your Shop Floor Runs on Experience — Not Data
Your best machine operator 'knows' when a machine is about to fail because they've heard that sound before. But when that operator retires or is on leave, nobody else catches the warning signs — and a ₹20,000 bearing failure becomes a ₹5,00,000 production stoppage. Tribal knowledge doesn't scale. Data does.
Your Production Reports Are 12 Hours Old by the Time Management Sees Them
The operator notes production counts on a register at the end of the shift. The supervisor compiles it into Excel in the morning. The plant head sees 'yesterday's production' at 11 AM. By then, a machine that was running slow all of yesterday's second shift has already caused another 4 hours of reduced output — and nobody knew until it was too late.
You Want Machine Data But Your Machines Are 20 Years Old with No Digital Output
Your CNC machines, injection molding presses, and conveyor systems are mechanical workhorses — but they were built before IoT was a thing. No sensors. No network ports. No data output of any kind. Every 'smart factory' vendor tells you to replace them with new IoT-ready machines at ₹20-50 lakhs each. You know there must be a retrofit option — but who builds that?
Your ERP Shows Stock but the Shop Floor Reality Is Completely Different
The ERP says 500 units of finished goods are in stock. The warehouse actually has 480 because 20 were rejected by QC but the rejection wasn't entered into the system. Production planning schedules the next batch based on the ERP's 500 number. Customer orders 100 units. You can only ship 80. This gap between 'system reality' and 'physical reality' costs you credibility with every customer.
Most ERP consultancies stop at software. We don't. We design and build the sensors, controllers, and IoT data pipelines that connect your physical machines to your digital systems — so what your ERP shows is what's actually happening on the ground. From PCB design to cloud dashboard — one team, one accountability:
How We Deliver
Detailed breakdown of what you get, how we do it, and what the result looks like.
Custom Industrial Controllers & Automation Systems
From concept to PCB to production-ready controller — designed for your specific application
Off-the-shelf PLCs and controllers work for standard applications. When your automation need is unique — a specific motor control sequence, a custom sensor configuration, an unusual communication protocol — we design and build the controller from scratch. PCB design, component sourcing, prototyping, firmware development, enclosure design, and testing — all under one roof.
What You Get
Real Scenario
An agri-equipment manufacturer needed a smart motor controller for remote pump operation across large agricultural fields — GSM-connected, solar-powered, with ultra-low-power sleep mode. We designed the PCB, wrote the firmware, prototyped 10 units, and tested them across 50+ farm installations. The controller uses 60% less power than their previous generation and reports pump status, runtime, and energy consumption to a cloud dashboard the farmer checks on their phone.
Retrofit IoT for Legacy Machines
Bring your 20-year-old machines online for under ₹5,000 per machine — without replacing anything
Your machines work fine — they just don't produce data. We build compact, industrial-grade sensor modules that clamp onto existing equipment (no modification needed), capture the data points that matter (uptime, cycle count, temperature, vibration, energy consumption), and transmit them to your ERP or cloud dashboard. No machine replacement. No production stoppage for installation.
What You Get
Real Scenario
A textile manufacturer runs 40 weaving looms — most of them 15-20 years old, zero digital output. Production data was collected on paper registers at the end of each shift. We designed a ₹3,500 retrofit sensor module that clamps onto each loom's frame, detects vibration patterns to determine run/stop status (no electrical connection needed), counts cycles, and transmits data via WiFi to a central gateway. Management now sees real-time loom utilization, shift-wise production, and downtime alerts — on a dashboard refreshed every 30 seconds.
IoT-to-ERP Data Pipeline
Machine data doesn't belong in a separate 'IoT platform.' It belongs in your ERP.
Most IoT projects fail at the 'so what?' stage — sensors collect data, the data goes to a beautiful cloud dashboard, and... nobody looks at it after the first week. We close the loop: IoT data flows directly into your ERP — production orders auto-update with actual quantities produced, inventory auto-adjusts, maintenance work orders auto-generate when vibration patterns indicate impending bearing failure.
What You Get
Real Scenario
A manufacturing plant's production data was entered into the ERP 6-8 hours after the fact — shift-end manual entries, often with errors. We deployed retrofit sensors on 25 critical machines, built an MQTT data pipeline to Azure IoT Hub, and connected it to their BC production module. Now when a machine completes 100 cycles, the production order in BC is auto-updated in real time. The production planning team sees live WIP status. Month-end production reconciliation — previously a 2-day exercise — now takes 30 minutes.
What Our Clients Typically Achieve
Per-machine retrofit cost to bring legacy equipment online — versus ₹20-50 lakhs to replace each machine with a new IoT-ready model
Reduction in unplanned downtime — vibration/temperature anomaly alerts catch problems before they become failures
Machine data flows into your ERP automatically — no more shift-end manual entries, no more 'system says 500 but warehouse has 480'
Hardware + firmware + cloud + ERP integration — designed and delivered by one team. No finger-pointing between hardware and software vendors
Our Process
A structured, milestone-driven approach that keeps you in control at every stage.
Shop Floor Assessment
We visit your plant. Map every machine. Identify what data matters. Assess connectivity, power, and physical constraints.
Hardware Design & Prototyping
PCB design, component sourcing, firmware development, enclosure design. Prototype tested on your actual machines.
Pilot Deployment
Deploy on 3-5 machines. Run for 2-4 weeks. Validate data accuracy. Refine based on real-world feedback.
ERP Integration
Build the data pipeline from devices → cloud → ERP. Configure dashboards. Set up alerts and automated actions.
Full Rollout & Training
Deploy across all machines. Train your maintenance and production teams. Hand over documentation, source code, and spare components.
Technology Stack
The tools, platforms, and technologies we use to deliver this service.
Production-Proven Results
Not a demo. Not a prototype. Deployed and running.
We designed an ESP32-based smart motor controller for an agri-manufacturer that reduced power consumption by 60% versus their previous generation, operates reliably across 50+ rural installations with GSM connectivity, and reports real-time pump status to a cloud dashboard the farmer accesses on their phone.
Frequently Asked Questions
Quick answers to common questions.
Ready to Solve This?
Tell us about your requirements and we'll show you exactly how we'd approach your embedded & iot project — with a concrete plan, timeline, and investment estimate.