Unifying 14 legacy controllers into one production brain
Unifying 14 legacy controllers into one production brain
What was breaking
A precision-components manufacturer ran fourteen machine controllers across three generations of hardware, none of which spoke to each other. Reconciling a single day's output meant two days of manual spreadsheet work, and four vendors had already declined the integration.
What we engineered
We mapped every controller's signal on-site, then engineered an OPC-UA and PLC bridge that normalised the telemetry into a custom ERP core. A unified job model gave the floor one live view across every machine, every shift, with automatic job closure.
What changed
Daily reconciliation dropped from two days to five hours, throughput visibility rose 31%, and all fourteen systems now feed a single source of truth the client owns outright.
Representative blueprints, real client screenshots shown under NDA on request.