Turn Plant Floor Data Into Manufacturing Intelligence
Non-invasive, platform-agnostic data pipelines from any automation vendor to Google Cloud. Real-time OEE, predictive maintenance, and AI-driven quality — deployed in weeks, not months.
Your Machines Generate Data. It Stays Trapped on the Plant Floor.
Mid-market manufacturers generate massive volumes of machine-level data through PLCs, SCADA systems, and sensors. But extracting that data for analytics means either invasive PLC modifications, expensive historian platforms, or $300K+ integration projects from Global Systems Integrators.
- PLC modifications risk production disruption on running lines
- Proprietary historian platforms lock data with limited AI capability
- GSI projects cost $300K-$500K — out of reach for most mid-market ops
- Shift reports are still manual; true OEE remains unknown
Works With Every Automation Vendor
Our edge gateway supports 270+ industrial protocols. Connect any PLC, DCS, SCADA, or IoT platform — without vendor lock-in.
Also supports Emerson, Mitsubishi, Fanuc, Beckhoff, Omron, Bosch Rexroth, GE, and 250+ additional protocols including MQTT, BACnet, OPC DA/HDA, and custom gateways.
Six-Layer Cloud-Native Pipeline
From PLC tag to executive dashboard in under 10 seconds. Every layer is serverless, auto-scaling, and secured by ISA/IEC 62443 zone controls.
OT Data Sources
PLCs, SCADA, HMI, sensors from any vendor
Edge Gateway
Manufacturing Connect edge – 270+ protocols, ISA-95 normalization.
MDE Pipeline
Pub/Sub + Dataflow: parse, transform, enrich, deduplicate
BigQuery
Three-tier lakehouse: Raw, Curated, Analytics zones
Vertex AI
Predictive maintenance, quality anomaly detection, OEE optimization
Looker
OEE Command Center, maintenance, quality, executive KPIs
Step 01
OT Data Sources
PLCs, SCADA, HMI, sensors from any vendor
Step 02
Edge Gateway
Manufacturing Connect edge — 270+ protocols, ISA-95 normalization
Step 03
MDE Pipeline
Pub/Sub + Dataflow: parse, transform, enrich, deduplicate
Step 04
BigQuery
Three-tier lakehouse: Raw, Curated, Analytics zones
Step 05
Vertex AI
Predictive maintenance, quality anomaly detection, OEE optimization
Step 06
Looker
OEE Command Center, maintenance, quality, executive KPIs
From Visibility to Prediction
Real-Time OEE Command Center
Replace manual shift reports with live OEE dashboards breaking down Availability, Performance, and Quality for every machine, line, and plant. Most manufacturers discover their actual OEE is 10-20 points below their estimate.
+15-20 pts
OEE improvement
< 30 sec
Data latency (was days)
100%
Shift report automation
4-6 wks
Time to deploy
AI-Powered Predictive Maintenance
Vertex AI models analyze vibration, temperature, motor current, and historical patterns to predict equipment failures before they happen. Integrated with SAP PM for automated work order creation.
25-40%
Unplanned downtime reduction
15-25%
Maintenance cost reduction
50-60%
MTTR improvement
6-8 wks
Time to deploy
AI Quality Intelligence
Autoencoder-based anomaly detection identifies quality deviations in real-time. SPC control charts, Cp/Cpk monitoring, first-pass yield tracking, and root cause analysis traced back to material lots and process parameters.
30-50%
Scrap/rework reduction
Real-time
SPC anomaly detection
Full
Material traceability
8-12 wks
Time to deploy
Energy and Sustainability Analytics
Monitor energy consumption per machine, per product, and per shift. Identify energy waste patterns, correlate consumption with production output, and track sustainability KPIs for ESG reporting.
10-20%
Energy cost reduction
Per-unit
Energy cost tracking
ESG
Sustainability reporting
Add-on
Builds on Phase 1
270+
Industrial Protocols Supported
< 10s
PLC Tag to BigQuery Latency
0
PLC Code Changes Required
40-50%
Cost Savings vs. GSIs
Value at Every Phase
Each phase delivers standalone business value. Start with OEE visibility in 4 weeks, expand to predictive AI as the data foundation matures.
1. OEE Visibility
4-6 weeks
- Connect 1-3 critical machines via edge gateway
- Provision MDE cloud pipeline to BigQuery
- Launch OEE Command Center in Looker
- Automated shift reports replace manual collection
Baseline OEE established. Real-time visibility live.
2. Predictive AI
6-8 weeks
- Expand to all critical equipment (10-30 machines)
- Deploy Vertex AI predictive maintenance models
- Integrate with SAP PM for automated work orders
- Equipment health scores and failure predictions
25-40% reduction in unplanned downtime.
3. Quality AI + Fusion
8-12 weeks
- Quality anomaly detection with Vertex AI
- Full SAP Cortex IT-OT data fusion
- Executive KPI dashboards across all plants
- Gemini-powered natural language queries
Complete manufacturing intelligence platform.
Industrial-Grade Security
Built to ISA/IEC 62443 standards with Purdue Model zone alignment. Your plant floor remains completely air-gapped from the cloud.
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Non-Invasive Access
Read-only OPC UA connections. Zero PLC modifications. Existing automation programs remain untouched. Deploy on running production with zero downtime.
OT DMZ Isolation
Edge gateway deployed in the OT DMZ with dual firewall configuration. Only outbound MQTT/TLS connections. No inbound access from cloud to plant floor.
Encrypted End-to-End
TLS 1.3 for data in transit, AES-256 for data at rest. mTLS authentication between edge and cloud. X.509 certificate-based device identity.
IAM + Zero Trust
GCP IAM with least-privilege service accounts. Workload Identity Federation for the edge gateway — no stored credentials on-premise. VPC Service Controls perimeter.
Audit and Compliance
Cloud Audit Logs for complete access audit trail. CMEK (Customer-Managed Encryption Keys) for BigQuery. DLP API scanning for PII in data streams.
Purdue Model Alignment
Architecture strictly follows ISA-95 / Purdue levels 0-5. Each zone boundary has explicit security controls. Plant floor operates independently if cloud disconnects.
Built Different for Mid-Market
Google Cloud Partner delivering non-invasive, platform-agnostic manufacturing data pipelines for mid-market discrete manufacturers
Ready to Unlock Your Plant Floor Data?
Schedule a 30-minute discovery call. We will assess your automation environment and map out a Phase 1 deployment plan — specific to your PLCs, your plant, and your goals.
