For plant, operations and reliability leaders
Manufacturing Data Integration
Your machines, MES, ERP and maintenance logs in one place, so the morning meeting runs on today's numbers.
Manufacturing data integration connects the systems on your floor with the ones in the office so they share one set of numbers. We've done it on a real line: 50 sensors and 10,000+ maintenance records pulled together, and unplanned downtime fell 25%.
Book a call and we'll send a 1-page plan. We start from exports, so IT doesn't need to open a ticket on day one.
25%
Less unplanned downtime in our manufacturing project
$500K
Maintenance savings on that same project
2–6 wks
Fixed-scope pilot before any long contract
100%
Your code and data, from day one
The problem
Six systems, six versions of the truth
Production says the press ran 22 hours. Maintenance says it was down for 4. Finance has a third number, from the ERP, and it's from last Tuesday.
So someone builds a spreadsheet every Monday to make them agree. It takes most of a morning. And by the time it's done the numbers are already old.
Cost of doing nothing
What unplanned downtime costs you each year
Move the sliders to match your plant. The default reduction is 25%, which is what we measured on our own manufacturing project. Yours could be lower or higher.
Downtime calculator
Saved per year
$480,000
Hours × cost per hour × 12 months × reduction. Cost per hour should include lost output, overtime, scrap and rush shipping.
How it works
One plant data layer, fed by the systems you already have
We read from each system, give every machine and part one shared ID, line up the timestamps and store it all in one place your team can query. Then we build the views people asked for.
Plant data layer
One asset ID per machine, one clock, data checked on the way in. Built on the ISA-95 model.
| Typical systems | Data speed | How we connect | |
|---|---|---|---|
| Levels 0–1: machines | Sensors, PLCs, drives | Milliseconds | Through SCADA or an edge gateway, never direct writes |
| Level 2: control | SCADA, HMI, historian | Seconds | OPC UA, MQTT, historian APIs |
| Level 3: operations | MES, CMMS, QMS, LIMS | Minutes to hours | SQL, REST APIs, scheduled exports |
| Level 4: business | ERP, planning, finance | Hours to days | ERP APIs, IDocs/BAPIs, flat files |
Proof
We've done this on a real line
25%
less unplanned downtime
$500K
maintenance savings
50
sensors unified
15
operators trained
A mid-sized manufacturer had data from 50 sensors and 10,000+ rows of maintenance history spread across sheets and systems. We pulled it into one place, trained 3 models to spot failures early, and gave the team one dashboard with alerts.
Read the full case studyThe plan
Your first 6 weeks
- 01Week 1
Walk the line
List systems, tags and exports. Agree on 2 or 3 numbers that matter (OEE, downtime, scrap). - 02Weeks 2–3
Connect and map
Read-only connections. Build the asset ID map. Align timestamps and shifts. - 03Weeks 4–5
First views live
Dashboard and alerts for one line. Your team checks the numbers against what they know. - 04Week 6
Decide
Review results against the success criteria we wrote down in week 1. Expand, change or stop.
Want this for one of your lines?
Send us the list of systems you run. That's enough to start.
What goes wrong
The problems nobody puts in the proposal
- Tag names. PLC tags like TAG_0042 with no description. Somebody on the floor knows what it is. Find them early.
- Clocks that disagree by a few minutes.
- Shift math. A night shift that crosses midnight will split your daily numbers in two unless you plan for it. Boring. Also the cause of about half the “the dashboard is wrong” tickets we see.
- IT and OT teams who have never been in the same meeting.
- Trying to connect all sites at once. Do one line, prove it, then copy the pattern (I'd argue this is the only rule that really matters here).
$119B
in preventable losses a year for US manufacturers from poor maintenance, $18.1B of it from downtime.
3.3×
more downtime at the most reactive plants (the ones that fix things after they break) than at the least reactive.
52.7%
less unplanned downtime at plants that lean on predictive and preventive maintenance, plus 78.5% fewer defects.
11%
of revenue lost to unplanned downtime at the world's 500 biggest companies. In automotive, about $2.3M an hour.
10–20%
more production output is what smart-manufacturing adopters report, with 10–15% more capacity freed up.
29%
of the average enterprise's apps are integrated with each other. The rest are islands.
Watch
Plant data, explained in plain words
Want the background on how plant systems are layered? This video walks through the ISA-95 pyramid, level by level.
Moving to a new ERP at the same time? Read data migration vs data integration first. And for the ERP-to-MES side, Walker Reynolds has a solid walkthrough.
Questions buyers ask
Straight answers before you book a call.
Pick one line. Get it connected in weeks.
Tell us which systems you run and what you wish you could see every morning. We'll come back with a scoped pilot plan.
Book a call and we'll send a 1-page plan. We start from exports, so IT doesn't need to open a ticket on day one.