Industry 4.0 That Works On Your Shopfloor.
We build the industrial software layer that connects your machines, people, and supply chain giving manufacturers real-time visibility, predictive intelligence, and operational control without ripping out what already works.
No real-time visibility into what’s happening on the shopfloor
Production data lives in clipboards, spreadsheets, and shift reports. Managers find out about quality issues or machine downtime hours after it happens when the damage is already done and the batch is already scrapped.
Unplanned downtime eating into OEE and margins
Equipment fails without warning. Maintenance is reactive fix it when it breaks. No early warning signals, no condition monitoring, no predictive alerts. A single unexpected breakdown can take out an entire production line for hours.
Supply chain and production planning done on gut feel
Raw material planning, production scheduling, and inventory management running on monthly reports and experience-based guesses. No demand signal integration, no dynamic reorder logic, no visibility beyond the four walls of the factory.
Industrial Software That Connects the Entire Operation
We build across the full manufacturing technology stack from IoT sensor integration on the shopfloor to supply chain visibility, quality management, and AI-powered production intelligence.
01
Shopfloor Visibility & MES
Real-time production monitoring, OEE tracking, downtime logging, and digital work orders giving plant managers live visibility into every line, shift, and machine without waiting for the morning report.
02
Predictive Maintenance
Machine health monitoring using IoT sensors and ML models detecting anomalies, predicting failures before they happen, and automatically scheduling maintenance to eliminate unplanned downtime.
03
Quality Management Systems
Digital inspection workflows, AI-powered visual defect detection, SPC charts, non-conformance tracking, and corrective action management reducing defect rates and rework costs at every stage of production.
04
Supply Chain & Inventory Intelligence
Demand-driven material planning, supplier performance tracking, RFID-based inventory visibility, and automated replenishment connecting production schedules to procurement in real time.
The Full Industrial Technology Stack
From IoT connectivity on legacy machines to AI-powered production planning we build modular, scalable industrial software that works within your existing infrastructure.
IoT & Machine Connectivity
Connecting legacy and modern machines via MQTT, OPC-UA, Modbus, and custom protocols streaming real-time production data to a unified platform without replacing existing equipment.
- OPC-UA
- MQTT
- Modbus
- Edge Computing
Manufacturing Execution System (MES)
Digital work order management, production scheduling, labour tracking, batch record management, and real-time OEE dashboards replacing paper-based shopfloor control with a connected digital layer.
- Work Orders
- OEE Tracking
- Batch Records
- Labour Mgmt
Computer Vision Quality Control
AI vision systems for automated defect detection, dimensional inspection, label verification, and packaging integrity checks running at line speed with real-time rejection and alert workflows.
- Defect Detection
- Dimensional QC
- Label Verification
- Real-time Alerts
ERP Integration & Data Unification
Bi-directional integration between shopfloor systems, ERP (SAP, Oracle, Microsoft Dynamics), and PLM platforms eliminating manual data entry and creating a single source of truth for production and finance.
- SAP Integration
- Oracle ERP
- PLM Connect
- Data Unification
Energy & Sustainability Monitoring
Real-time energy consumption tracking per machine, shift, and product identifying waste, benchmarking against targets, and building the data foundation for ESG reporting and carbon reduction programmes.
- Energy Metering
- ESG Reporting
- Carbon Tracking
- Cost Allocation
Production Analytics & AI Planning
ML-driven production scheduling, yield prediction models, bottleneck analysis, and demand-driven capacity planning turning historical production data into forward-looking operational intelligence.
- Scheduling AI
- Yield Prediction
- Bottleneck Analysis
- Capacity Planning
Built for Industrial Environments & Compliance
Manufacturing software must meet strict quality, safety, and interoperability standards. We design for compliance from the start so audits don’t require rework.
Quality Management
QMS-aligned digital workflows, document control, CAPA management, and audit-ready records for ISO 9001 and IATF 16949 certified manufacturers.
Manufacturing Integration
ISA-95 compliant MES-ERP integration architecture ensuring standardised data exchange between shopfloor systems and enterprise planning layers.
Machine Interoperability
Industry-standard OPC-UA connectivity for machine data works across legacy PLCs, CNCs, SCADA systems, and modern smart machines without vendor lock-in.
Pharma & Food Compliance
21 CFR Part 11, EU GMP Annex 11, and FSMA-aligned electronic batch records, audit trails, and electronic signatures for regulated manufacturing sectors.
Auto components manufacturer reduced unplanned downtime by 73% with predictive maintenance
A mid-size automotive components manufacturer with 14 CNC machining centres was experiencing an average of 22 hours of unplanned downtime per month. Maintenance was entirely reactive machines failed, production stopped, and technicians scrambled. OEE was sitting at 61%, well below the industry benchmark of 85%.
The challenge: Connect legacy CNC machines to an IoT monitoring layer, build ML models to detect anomalies in vibration, temperature, and spindle load data, and integrate alerts into the maintenance team’s workflow without disrupting ongoing production.
Kulsys Technologies deployed edge IoT gateways on all 14 machines, built a real-time anomaly detection layer using vibration and thermal sensor data, and integrated predictive alerts into a mobile maintenance app deployed in 11 weeks with zero production disruption.
Outcomes Delivered
73%
Reduction in unplanned downtime hours
OEE 81%
Up from 61% within 3 months
44%
Reduction in maintenance cost per machine
11 wk
Full deployment with zero downtime
We Build for the Shopfloor, Not Just the Boardroom
Industrial software has to work in noisy, dusty, connectivity-challenged environments and it has to be usable by operators on shift, not just analysts in the office.
Works Without Cloud
Edge computing architecture means shopfloor systems keep running even when internet connectivity drops no factory-wide outage because of a network blip.
Connects Old Machines
We connect 20-year-old PLCs and CNCs to modern platforms using protocol adapters no need to replace expensive machinery to get digital visibility.
Start Small, Scale Fast
Deploy on one line first, prove the ROI, then roll out across the plant or multiple sites our modular architecture is designed for phased implementation.
Measurable from Day One
Every project starts with a baseline measurement and defined KPIs. You’ll know exactly what the system is delivering in reduced downtime, scrap, and cost.
Let’s Digitise Your Manufacturing Operations
Tell us about your plant, your current challenges, and where you’re losing time or money on the shopfloor. We’ll come back with a clear technology roadmap and a measurable first step.
- Free operations assessment for qualified manufacturers
- Response within 1 business day
- Modular approach start with one line or one problem
- Experience across automotive, pharma, FMCG, electronics & metals
Start a Conversation
Other Industries We Serve
Smart Mobility & Logistics
Fleet management, route optimisation, warehouse systems, and last-mile delivery platforms for logistics operators who can’t afford downtime.
Healthcare & MedTech
Compliant, interoperable digital health systems for hospitals, MedTech companies, and health platforms built for clinical realities.
Retail & E-Commerce
Omnichannel platforms, inventory intelligence, personalisation engines, and last-mile operations for modern retail businesses.