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Your Shop Floor Runs Blind Because Your MES Can't Talk to Your ERP

If you're a plant manager watching operators copy-paste production counts into spreadsheets, you're running a $50M facility on Excel and hope.

We build Next.js shop floor interfaces and MQTT data pipelines that pull live machine telemetry into OEE dashboards and push confirmed production counts directly into your ERP — eliminating the manual entry loop that costs your operators two hours per shift and gives your planners stale numbers.

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Manufacturing Software Development

Manufacturing software development covers the custom web applications, protocol bridges, and ERP connectors that sit between your plant equipment and your business systems. We specialise in Next.js kiosk interfaces, MQTT and OPC-UA data collection layers, and REST or EDI integrations with systems like SAP, Epicor, and NetSuite. The output is a single source of truth for shift output, downtime, and quality data that updates in seconds, not the next morning.

What is holding your current website back?

Common gaps we find in nearly every audit.

Operators record production counts on paper or in spreadsheets, then a data-entry clerk transcribes them into the ERP hours later.
Risk: Planners schedule the next day's jobs on numbers that are already wrong, leading to missed customer commitments and reactive overtime.
Your MES vendor provides an OEE report, but it runs as a batch job overnight and excludes downtime shorter than the polling interval.
Risk: Short stoppages — the category that typically accounts for 30-40 percent of lost capacity — are invisible, so root-cause work never starts.
Machine PLCs speak Modbus or MQTT and your ERP speaks REST or SOAP, and no one on your internal team owns both sides of that gap.
Risk: Integration projects stall for months in vendor blame cycles while the spreadsheet workaround becomes permanent and grows more fragile every week.

How We Build This Right

Every safeguard, built in from Day 1.

Network Segmentation

We design OT-to-IT data flows that keep plant equipment on an isolated network segment, with a one-way data diode or DMZ broker so a web vulnerability cannot reach a PLC.

Audit-Ready Data Lineage

Every production record written to the ERP carries a timestamp, operator ID, and machine source tag, giving quality auditors a traceable chain from raw sensor reading to posted transaction.

Role-Based Access Control

Kiosk screens presented to operators contain only the actions their role permits. Supervisor overrides, scrap dispositions, and ERP write-backs require authenticated sessions with logged approval.

What We Build

Purpose-built features for your industry.

Live OEE Dashboard

A Next.js dashboard subscribes to your MQTT broker and renders availability, performance, and quality rates per machine, per line, and per shift with sub-five-second latency. No overnight batch, no manual refresh.

Shop Floor Kiosk Interface

Touchscreen-optimised kiosk pages let operators log job starts, quantity counts, scrap reasons, and downtime codes directly at the machine. Data posts to the database immediately and triggers ERP transactions without a second manual step.

ERP Connector and Sync Engine

We build a typed connector layer — REST, EDI, or SOAP depending on your ERP — that maps confirmed production quantities to work order confirmations, inventory movements, and labour postings on a configurable schedule or event trigger.

Downtime and Maintenance Alerting

When a machine stops producing for longer than a configurable threshold, the system fires an alert to the responsible technician via SMS or a Teams webhook, logs the event with a reason code, and updates the OEE calculation in real time.

Our Development Process

From discovery to launch. Quality at every step.

01

Shop Floor Audit and Data Mapping

1-2 weeks

We spend time on the plant floor documenting machine protocols, PLC tag structures, existing MES outputs, and the exact fields your ERP expects for each transaction type. We leave with a data dictionary and a gap list before writing a line of code.

02

MQTT Broker and Collection Layer

1-2 weeks

We configure or deploy a broker, write the topic schema, and connect your machines — via existing MQTT clients, Modbus-to-MQTT bridges, or OPC-UA adaptors. You get a working telemetry stream you can query before the UI is built.

03

Kiosk UI and OEE Dashboard Build

2-4 weeks

We build the Next.js operator kiosk and supervisor dashboard against the live data stream. Shift leads and operators test real screens with real machine data during this phase so layout and workflow problems surface early.

04

ERP Integration and Go-Live

1-2 weeks

We connect the production database to your ERP through the agreed connector, run parallel posting for one full shift to verify transaction accuracy, then cut over. Handover includes runbook documentation and a one-month support window.

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Frequently Asked Questions

A single-line OEE dashboard with MQTT ingestion and Supabase backend starts around $40K. Multi-plant systems with ERP integration, quality portals, and kiosk UIs land between $100K and $200K. We scope fixed-price after the Week 1 audit so you won't get a surprise change order. The biggest cost variable is the number of ERP and PLC integrations -- each connector adds roughly $8K-$15K depending on API documentation quality.
Most teams see a working staging dashboard by Week 5. Production rollout for a single facility typically wraps by Week 8-10. Multi-plant deployments stagger after that -- usually 2-3 weeks per additional site once the core platform is stable. We don't do 6-month waterfall timelines. You'll see working software every two weeks.
Traditional MES platforms charge per-seat licenses, lock you into proprietary databases, and take 6-12 months to customize. Next.js gives you server-rendered dashboards that load in under a second on a $200 kiosk tablet. Supabase gives you a full Postgres database with real-time subscriptions, row-level security, and zero per-seat fees. You own the code, you own the data, and you can hire any React developer to maintain it. We've replaced $80K/year SaaS contracts with this stack.
Yes. We work with Modbus TCP, OPC-UA, and MQTT-native devices. For older PLCs that only speak Modbus or proprietary protocols, we deploy an edge gateway (typically a Raspberry Pi or Advantech box running Node-RED or Ignition Edge) that translates to MQTT. Your existing SCADA stays untouched -- we read from it, we don't replace it unless you want us to.
The kiosk UI is built offline-first with service workers and IndexedDB caching. Operators can keep logging defects and scanning work orders. When connectivity returns, queued records sync to Supabase automatically. On the telemetry side, the MQTT broker and edge gateway buffer messages locally until the upstream connection recovers. We've tested this with 4-hour outage simulations -- zero data loss.
A standard engagement runs with a 3-4 person squad: one senior full-stack engineer (Next.js + Supabase), one IoT/integration engineer handling MQTT and PLC connectivity, one UI engineer for kiosk and dashboard work, and a project lead who's done manufacturing installs before. For multi-plant builds we'll scale to 5-6. Everyone's W-2 or long-term contract -- no random freelancer rotation.
We offer monthly retainers starting at $3K/month that cover Vercel and Supabase infrastructure monitoring, MQTT broker health checks, dependency updates, and up to 20 hours of feature work. Most manufacturing clients stay on retainer for at least the first year because production requirements shift with new product lines. You'll get a dedicated Slack channel and a 4-hour response SLA during business hours.
Supabase row-level security policies enforce plant-level and role-level access out of the box. All data is encrypted at rest (AES-256) and in transit (TLS 1.3). We support SSO via SAML or OIDC for enterprise IT requirements. For regulated industries, we've built to FDA 21 CFR Part 11 requirements including electronic signatures and full audit trails stored in Postgres. You'll get a security architecture doc as part of the Week 2-3 deliverable.
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