Manufacturing
IoT-enabled production monitoring, predictive maintenance dashboards, ERP integrations.
How we work in manufacturing
RNDSOL is a manufacturing software development company building IoT production monitoring, predictive maintenance systems, and ERP integrations that answer questions with data pulled straight off the shop floor. Because factories don't need more dashboards; they need to know which machine will fail next week, what this batch actually cost, and why line two is 6% slower than line three.
Our predictive maintenance work speaks for itself: for one manufacturer we instrumented 40+ machines, trained failure-prediction models on vibration and temperature data, and cut unplanned downtime by a third. The hard part wasn't the machine learning. It was OT/IT integration, getting 20-year-old PLCs talking to a modern data platform over OPC UA and MQTT without disturbing production.
We also live on the business side of manufacturing. Our Linetig ERP unifies inventory, finance, and production in one ledger, and we've integrated shop-floor systems with SAP, Odoo, and plenty of homegrown ERPs. Built and supported from Lahore, Pakistan, with deployments serving plants in the Gulf.
What we build
The problems that bring teams to us
These are the patterns we see most often in manufacturing engagements, and how we handle them.
OT/IT convergence without downtime
Production networks weren't designed to feed cloud analytics, and nobody will halt a line for your integration. We deploy edge gateways that read from PLCs and sensors passively, with network segmentation that keeps the OT side isolated from anything internet-facing.
Predictive maintenance that earns trust
A model that cries wolf gets ignored within a month. We tune alert thresholds with your maintenance team, start with the two or three failure modes that cost you most, and expand only after the predictions prove out.
True cost per unit
Most plants know their costs quarterly and approximately. We build shop-floor costing that ties material, labour, energy, and scrap to each batch, so pricing decisions rest on numbers instead of instinct.
ERP integration debt
Production data trapped in one system and financials in another means Friday afternoons lost to reconciliation spreadsheets. We build the integration layer that makes them one system in practice.
How a project runs
Walk the floor first
Discovery happens at the plant, not on a video call. We trace material flow, talk to operators and maintenance crews, and inventory every data source from PLC tags to paper logbooks.
Edge collection, cloud analytics
Gateways buffer and forward sensor data over MQTT, so a dropped connection loses nothing. Heavy analysis runs in the cloud where compute is cheap; time-critical alerts evaluate at the edge.
Prove value on one line
We pick one production line and one costly failure mode, deliver a working system in a quarter, and let measured downtime numbers make the case for expanding.
Hand over with training
Maintenance planners and production managers get trained on the system as part of delivery, because software that only the IT department understands changes nothing on the floor.
Built to the rules your sector runs on
Standards and regulations we design against in this industry. Your compliance team owns interpretation; our job is making the system enforce it.
Predictive Maintenance for a Manufacturer
A manufacturer wanted to reduce unplanned downtime by using sensor data from production equipment.
Questions we hear from teams like yours
Usually, yes. Older PLCs often expose more than expected via serial or fieldbus protocols, and where they expose nothing we retrofit sensors for vibration, current draw, and temperature. Retrofit sensors alone are enough for most predictive maintenance use cases.
Our manufacturing case study client saw roughly a one-third cut in unplanned downtime within a year, and that's consistent with what focused predictive maintenance programs achieve. The bigger surprise is usually the scheduling benefit: maintenance moves to planned windows instead of emergencies.
Yes. We've integrated shop-floor systems with SAP, Odoo, and custom ERPs, and our own Linetig ERP was built for exactly this kind of unified operation. Production orders flow down, actuals flow back up, and reconciliation stops being a manual job.
No. We deploy fully on-premise where policy or connectivity requires it. Plenty of plants run our stack on local servers with cloud sync as an optional, outbound-only layer.
Talk to us about your manufacturing project
A 30-minute call with an engineer, not a salesperson. We'll tell you what we'd build, what we wouldn't, and what it's likely to cost.