IoT & PLC Telemetry Integration
Connect machine sensors, robotics, and PLCs to digital gateways using industry-standard protocols (OPC UA, MQTT, Modbus).
MANUFACTURING & INDUSTRIAL OPERATIONS
Engineering for connected manufacturing and supply operations.
Build and modernize industrial platforms with real-time machine telemetry, material tracking, and end-to-end operational visibility. Teknalogi translates physical factory floor processes into precise, resilient digital systems.
Discuss your factory requirements
CONNECTED FACTORY
When factory systems operate separately, efficiency drops.
Operations become difficult to manage when machine, quality, and supply systems run independently.
- 01
Disconnected production data
Machine output and shift logs remain inconsistent across lines.
- 02
Manual quality logs
Paper-based inspection records delay defect detection and audit checks.
- 03
Unplanned downtime
Lack of telemetry leaves equipment wear undetected until line stoppages occur.
- 04
Supply chain blindspots
Uncertain vendor deliveries and material delays trigger line bottlenecks.
Manufacturing software tailored to your industrial workflows.
Discovery on the factory floor defines the scope so software architecture, IoT sensors, and workflows match active production lines.
Digital Work Orders & MES
Deliver interactive digital work instructions to operator tablets with cycle time tracking and real-time station progress.
Batch Traceability & Genealogy
Track material genealogy from supplier raw material lots to customer-delivered finished serials.
Predictive Maintenance & OEE
Calculate Availability, Performance, and Quality metrics automatically with proactive equipment anomaly alerts.
Inventory & Warehouse Sync
Synchronize Just-in-Time material stock, automated Purchase Order triggers, and multi-warehouse distribution.
Supplier & Supply Chain Portal
Provide collaborative vendor portals for delivery scheduling, Certificates of Analysis (COA) uploads, and order confirmation.
Designed for shop floor reliability and operational precision.
01 CONTROL
Industrial Data Integrity
Standardize machine telemetry, implement offline-first edge processing, and automate central synchronization.
02 BOUNDARY
OT/IT Network Segmentation
Design multi-tier security architectures (ISA/IEC 62443) with IDMZ boundaries separating factory controls from office IT.
03 READINESS
Plant Operational Resilience
Test failure tolerance against local network dropouts, edge server failovers, and rapid disaster recovery protocols.
Digital Manufacturing Systems Engineering & Automation
Table of Contents
Shop Floor & Industrial IoT Telemetry
Modern manufacturing requires real-time data flow from the production floor to executive dashboards. Industrial machines, sensors, and Programmable Logic Controllers (PLCs) often operate on proprietary protocols isolated from corporate IT systems.
Teknalogi builds industrial middleware that ingests telemetry from diverse sensors and PLCs via standard protocols like OPC UA, MQTT, and Modbus, transforming raw operational signals into structured data for enterprise intelligence.
- Industrial Protocol Standardization: Connecting machines across generations via IoT gateways to aggregate speed, temperature, vibration, and run-status without interrupting PLC scan cycles.
- Factory-Floor Edge Computing: Preprocessing critical telemetry on local edge gateways for instant threshold alerting, ensuring continuity regardless of internet latency.
- Real-Time Operational Dashboards: Live visualization of line performance across operator terminals and control rooms to resolve production bottlenecks quickly.
Unified machine connectivity gives production leaders complete transparency into line efficiency across every work shift.
Manufacturing Execution Systems (MES) & Work Orders
Translating ERP production schedules into daily shop floor execution frequently breaks down when relying on manual paperwork and disconnected spreadsheets.
We engineer custom MES modules that digitize work order distribution, workstation progress tracking, and machine capacity scheduling with pinpoint accuracy.
- Digital Work Orders & SOPs: Delivering production orders directly to operator tablets with interactive standard operating procedures and mandatory parameter checks.
- Automated Cycle Time Tracking: Logging exact operational durations per station to detect deviations from planned takt times and process standards.
- Dynamic Resource Scheduling: Automatically rebalancing production queues when customer priorities shift or machine availability changes unexpectedly.
Tailored MES deployments eliminate administrative lag between processing stages and maximize daily plant throughput.
Quality Control, Traceability & Batch Genealogy
Ensuring product quality and meeting rigorous compliance standards (ISO 9001 / IATF 16949) demands indelible records of every production batch.
We integrate barcode, QR code, and RFID tracking systems that record complete material genealogy from raw material intake through blending, assembly, and final packaging.
- End-to-End Material Traceability: Instant bi-directional mapping linking supplier raw material lot numbers directly to customer-delivered finished serials.
- Automated Quality Inspection Logging: Direct digital measurement and sensor capture recording dimensional tolerances and weight parameters without manual entry.
- Automated Defect Containment: Immediate digital quarantine of non-conforming batches, preventing defective subassemblies from moving downstream.
Comprehensive batch traceability streamlines customer compliance audits and resolves warranty claim investigations in minutes.
Predictive Maintenance & OEE Optimization
Unplanned machine downtime represents one of the largest sources of operational loss in manufacturing facilities.
By continuously monitoring equipment health indicators, we build systems that identify mechanical degradation patterns before failure occurs, while calculating Overall Equipment Effectiveness (OEE) objectively.
- Automated OEE Calculation: Continuous measurement across the three vital manufacturing pillars: Availability, Performance, and Quality.
- Early Anomaly Detection: Automated alerts triggered when sensors capture vibration spikes, thermal buildup, or abnormal current draw.
- Condition-Based Maintenance: Scheduling maintenance based on actual runtime hours and component stress rather than static calendar intervals.
Predictive maintenance workflows maximize equipment lifespan and eliminate costly emergency repair disruptions.
Supply Chain & Raw Material Orchestration
Raw material shortages bring assembly lines to a standstill, while excessive inventory ties up valuable working capital.
We build supply chain orchestration modules that synchronize plant production schedules with warehouse inventory levels, vendor purchase orders, and outbound logistics.
- Just-in-Time Inventory Safeguards: Dynamic safety stock thresholds calculated automatically against active production orders and supplier lead times.
- Collaborative Supplier Portal: Shared vendor consoles to monitor material demand, upload Certificates of Analysis (COA), and confirm shipment dates.
- Multi-Warehouse Inventory Visibility: Unified tracking of raw materials and finished goods across factory warehouses, distribution hubs, and customer transit.
Synchronized supply workflows ensure material readiness while maintaining lean inventory turnover.
Industrial Security & OT/IT Network Segmentation
Smart factory initiatives introduce new cybersecurity risks if Operational Technology (OT/SCADA) networks connect to corporate internet interfaces without strict segregation.
We implement multi-tier industrial security architectures aligned with ISA/IEC 62443, using Industrial Demilitarized Zones (IDMZ) to isolate shop floor controllers from business IT systems.
- Strict OT and IT Network Segmentation: Physical separation and firewall rule policies ensuring enterprise office traffic cannot execute direct commands on machine PLCs.
- Secure Remote Access Gateways: Multi-factor authentication and session-bound encryption for authorized equipment vendor diagnostics.
- PLC & SCADA Configuration Backup: Automated scheduled backups of machine firmware, recipes, and setpoint configurations for rapid disaster recovery.
Rigorous industrial security protects manufacturing plants against operational downtime and malicious cyber threats.
What teams usually discuss before a manufacturing project starts.
Machine configurations, communication protocols, and plant workflows vary widely. Technical discovery maps shop floor topology, risks, and implementation scope.
Can Teknalogi connect to legacy industrial machinery?
Yes. We deploy external IoT gateways and auxiliary sensor arrays to capture digital and analog signals from legacy machines without altering core PLC programming.
How does the system handle factory internet outages?
Our architecture leverages Edge Computing and local-first data caching. Local plant gateways continue capturing telemetry and executing critical logic, synchronizing with the central server once connectivity restores.
Can this platform integrate with enterprise ERP systems like SAP or Oracle?
Yes. We engineer robust API adapters and middleware connecting Manufacturing Execution Systems (MES) directly with your ERP inventory, purchasing, and finance modules.
How is quality and traceability data recorded on the plant floor?
Data capture is automated through barcode/QR scanners, RFID tags, digital scales, and automated vision inspection cameras positioned at critical workstations.
Does software deployment require shutting down production lines?
No. Sensor installation and software testing are conducted incrementally per workstation or during scheduled routine maintenance windows to avoid disrupting production.
What does the factory discovery phase cover?
We map line layouts, machine communication protocols, current logging methods, critical downtime causes, and enterprise integration requirements.
How is cybersecurity enforced on factory machine networks?
We implement strict OT/IT network segmentation, encrypted internal communication channels, role-based access control (RBAC), and isolated remote vendor access.
Does Teknalogi provide post-launch support and maintenance?
Yes. We offer dedicated SLA maintenance packages including telemetry monitoring, security patching, and rapid emergency technical assistance tailored to your plant operating hours.
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