Manufacturing
Smart factory software that turns production data into competitive advantage.
Manufacturing competitiveness increasingly depends on software — from MES systems that orchestrate production lines to AI models that predict equipment failure before it happens. Palsoro builds the digital factory infrastructure that connects machines, people, and enterprise systems to eliminate unplanned downtime, reduce defect rates, and accelerate production throughput.
What you get
What Manufacturing businesses
get with Palsoro
Manufacturing Execution System
Custom MES that orchestrates production orders, tracks work-in-process, manages labour assignments, and enforces quality gates — providing real-time production visibility from shop floor to executive dashboard.
Predictive Maintenance AI
Sensor data ingestion pipelines feeding ML models that detect anomalies in vibration, temperature, and current draw patterns — predicting equipment failure 48–72 hours before it occurs to eliminate unplanned downtime.
Quality Control Automation
Computer vision inspection systems, automated SPC charting, and defect root-cause analysis tools that reduce scrap rates and enable real-time process correction before defects compound.
Key benefits
Why Manufacturing companies choose Palsoro
Reduced Unplanned Downtime
Predictive maintenance AI typically reduces unplanned downtime by 30–50%, translating directly into higher OEE and avoided production loss revenue.
Lower Defect and Scrap Rates
Real-time SPC monitoring and computer vision inspection catch process deviations at the source, reducing scrap and rework costs by 20–40%.
Real-Time Production Visibility
Live OEE dashboards, bottleneck identification, and shift performance reporting give operations managers the data to make corrections on the same shift, not the next morning.
Faster Order Fulfilment
MES-driven production scheduling and digital work instructions reduce setup times and WIP queue times, compressing lead times and improving on-time delivery.
Seamless ERP Integration
Bidirectional MES-ERP integration eliminates manual data re-entry between shop floor and enterprise systems, improving inventory accuracy and cost accounting.
Solutions we build for Manufacturing
Manufacturing Execution System
Custom MES with production scheduling, work order management, digital work instructions, labour tracking, quality hold management, and OEE reporting.
Predictive Maintenance Platform
IoT sensor ingestion platform with time-series anomaly detection, remaining useful life prediction models, and maintenance work order generation integrated to your CMMS.
Digital Twin Environment
3D process simulation models updated in real time from shop floor sensor data — enabling virtual commissioning, what-if scenario planning, and training without production risk.
Computer Vision Quality Inspection
Deep learning visual inspection systems for surface defect detection, dimensional measurement, label verification, and assembly completeness checking at production-line speeds.
ERP Integration Layer
Bidirectional integration between your MES and SAP, Oracle, Microsoft Dynamics, or Epicor — synchronising production orders, inventory transactions, and cost postings automatically.
Statistical Process Control (SPC) Dashboard
Real-time control charts, process capability indices, and out-of-control alerts delivered to quality engineers and operators — triggering automatic process adjustment where feasible.
Supplier Quality Portal
Digital incoming inspection workflow, supplier scorecard dashboards, corrective action request management, and approved supplier list integration for procurement teams.
Our process
Our approach to Manufacturing development
Plant Floor Assessment
We walk the production floor, audit existing data sources (PLC historians, SCADA, ERP), and quantify the cost of downtime, defects, and data gaps before designing a solution.
IIoT & System Design
We design the sensor network, data ingestion architecture, edge computing requirements, and enterprise integration plan — aligning OT and IT teams on a shared technical roadmap.
Line-by-Line Deployment
We deploy MES and predictive maintenance one production line at a time — proving value and refining models before expanding to the full facility, minimising disruption to ongoing production.
Continuous Model Improvement
Predictive models retrain monthly on new sensor data. We run quarterly OEE reviews to identify further automation opportunities and product line expansions.
Why Manufacturing businesses trust Palsoro
OT/IT Convergence Expertise
We understand both operational technology (PLCs, SCADA, historians) and enterprise IT systems — bridging the gap that causes most smart factory projects to stall.
No Black-Box AI
Our predictive maintenance models produce explainable outputs — operators see which sensor readings triggered an alert and why, building the trust needed for adoption on the shop floor.
Proven MES Architecture
Our MES framework has been deployed in discrete, process, and hybrid manufacturing environments. We adapt it to your specific production model rather than forcing your operations into a rigid template.
Yes. We build data ingestion connectors for OPC-UA, Modbus, PROFINET, and direct historian APIs (OSIsoft PI, Honeywell PHD, Aspen InfoPlus). We can extract time-series data from virtually any industrial control system.
Initial models trained on historical failure data typically achieve 80–88% prediction accuracy at launch. Accuracy improves to 92–96% over 3–6 months of live operation as the model trains on your specific equipment behaviour.
Our vision systems are designed to augment inspection — automating high-volume, repetitive checks at machine speed while routing ambiguous cases to human reviewers. Full replacement of human inspectors is possible for specific, well-defined defect categories.
Yes. We build multi-site MES architectures with centralised dashboards, cross-site production balancing, and standardised quality processes — while accommodating site-specific configuration differences.