How do you connect to existing plant equipment and SCADA systems?

We use industry-standard OT protocols — OPC-UA, Modbus TCP, MQTT, and PROFINET — along with edge computing gateways (AWS Greengrass, Azure IoT Edge) to collect data from PLCs, CNCs, and SCADA systems without modifying the control logic or disrupting production.

How long does a predictive maintenance project take?

A focused predictive maintenance deployment on 5–10 critical assets typically takes 12–16 weeks from sensor installation to production alert. This includes data collection, model training, validation against historical failure events, and integration with your CMMS. Broader plant-wide programmes are phased over 6–12 months.

Can your AI quality inspection system work at production line speed?

Yes. We use dedicated GPU inference hardware (NVIDIA Jetson, Intel NCS) for edge inference, achieving inspection throughputs exceeding 200 parts per minute with sub-50 ms latency. Camera selection, lighting design, and model architecture are all calibrated to your specific line speed and defect type.

How do you ensure cybersecurity in an IIoT deployment?

We follow the IEC 62443 industrial cybersecurity standard: network segmentation between OT and IT zones, encrypted data transport from edge to cloud, certificate-based device authentication, and role-based access control at every layer. We also conduct vulnerability assessments of the OT network before any connectivity is established.

Can you integrate your platform with our SAP system?

Yes. We have production SAP integrations using RFC/BAPI calls, SAP Integration Suite (CPI), and REST APIs for both ECC and S/4HANA. Common integration points include production orders, material documents, quality notifications, plant maintenance work orders, and batch management.

Manufacturing & Industry 4.0

Manufacturing Software Development Company

Accelerate Industry 4.0 with intelligent automation, IoT, and smart factory platforms.

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70+

Manufacturing Products Built

25%

Avg. OEE Improvement

$300M+

Cost Savings Delivered

20+

Countries Deployed

Solutions

Industry Solutions We Build

Manufacturing ERP

Industry-specific ERP modules covering production planning, BOM management, shop-floor control, costing, and procurement for discrete and process manufacturers.

Quality Management System (QMS)

ISO 9001-aligned QMS platforms covering non-conformance management, CAPA workflows, SPC charting, and supplier quality programmes.

Production Planning & Scheduling

Advanced planning and scheduling (APS) tools with finite capacity scheduling, constraint modelling, and what-if scenario simulation.

Asset Performance Management

APM platforms that track asset health indices, failure history, maintenance costs, and OEE for every critical piece of plant equipment.

IoT Smart Factory Platform

Edge-to-cloud IIoT platforms that connect PLCs, CNCs, SCADA systems, and sensors to provide a live digital representation of the factory floor.

Predictive Maintenance System

ML models trained on vibration, temperature, current, and pressure data that predict equipment failure days in advance to enable condition-based maintenance.

Warehouse & Inventory Management

Raw material, WIP, and finished-goods inventory management with bin-level tracking, cycle counting, and MRP-integrated replenishment.

Digital Twin Platform

3D simulation environments synchronised with live sensor data to model production line behaviour, test process changes, and optimise throughput virtually.

Services

Development Services We Offer

Manufacturing Software Development

Custom MES, QMS, and ERP module development purpose-built around your production processes, integrated with your existing plant systems.

IIoT Platform Development

End-to-end Industrial IoT solutions from edge device connectivity through cloud data ingestion, storage, and real-time analytics dashboards.

Predictive Maintenance Solutions

Full-stack predictive maintenance programmes covering sensor selection, data pipeline, ML model development, and maintenance workflow integration.

MES (Manufacturing Execution System)

Real-time production dispatch, labour tracking, quality recording, and genealogy/traceability systems that bridge ERP planning with shop-floor execution.

Digital Twin Development

Physics-informed and data-driven digital twin models of assets, lines, and facilities that enable virtual commissioning and continuous process optimisation.

ERP Integration & Customisation

Integration and custom module development for SAP S/4HANA, Microsoft Dynamics 365, and Oracle Manufacturing Cloud with shop-floor and IIoT system connectivity.

Ready to Build for Manufacturing?

Our experts are ready to design and deliver the right solution for your manufacturing business — fast, secure, and built to scale.

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Innovation

Emerging Technologies in Manufacturing

⚡AI Quality Inspection

Computer vision systems deployed at production line speed that detect surface defects, dimensional deviations, and assembly errors with greater consistency than manual inspection.

⚡Predictive Maintenance AI

Multi-variate anomaly detection and remaining-useful-life (RUL) prediction models that extend asset lifespan and reduce unplanned downtime by up to 45%.

⚡Digital Twin Simulation

Real-time synchronised virtual models of production assets and lines that predict the impact of parameter changes, schedule optimisations, and new product introductions.

⚡Autonomous Robots Integration

Software orchestration layers that integrate AMRs, cobots, and automated conveyor systems into unified production scheduling and WIP tracking workflows.

⚡Computer Vision for Assembly

AI systems that verify correct assembly sequences, component placement, and torque application in real time, reducing rework and warranty claims.

⚡Real-Time OEE Dashboards

Live Overall Equipment Effectiveness dashboards that decompose availability, performance, and quality losses to the shift, line, and operator level for rapid root-cause analysis.

Use Cases

How We Help Manufacturing Businesses

Building a Smart Factory IIoT Platform

Connect 500+ PLCs, CNCs, and sensors via OPC-UA, Modbus, and MQTT edge gateways
Stream machine telemetry to the cloud at 1-second granularity for real-time process monitoring
Build operator-facing HMI dashboards showing live production counts, cycle times, and alarms
Create shift-level OEE reports auto-published to operations managers every 8 hours

Deploying Predictive Maintenance

Instrument critical assets with vibration, temperature, and current sensors at bearing and motor level
Train anomaly detection models on normal operating signatures to identify early degradation patterns
Integrate predicted failure alerts into the CMMS to auto-generate work orders before failure occurs
Track maintenance cost per asset and reduction in unplanned downtime on a rolling 12-month basis

Implementing AI Visual Inspection

Deploy high-speed industrial cameras at key inspection points in the production line
Train convolutional neural network defect classifiers on labelled image datasets from your process
Integrate inspection results with the QMS to trigger CAPA workflows on out-of-spec detections
Measure false-positive and false-negative rates and retrain models as product and process evolve

Launching a Digital Twin

Build a 3D physics model of a production line calibrated against real sensor data from the plant
Run virtual experiments to test the impact of speed increases, tooling changes, and maintenance intervals
Synchronise the twin with live OPC-UA data for real-time process state comparison
Use twin simulation to shorten new product introduction time by validating process parameters virtually

Implementing a Production MES

Configure work order dispatch, operator login, and real-time production count collection on the shop floor
Build component traceability capturing serial/lot numbers at every assembly operation
Integrate MES with ERP for real-time WIP inventory updates and production-vs-plan variance reporting
Provide quality recording at process steps with automatic hold triggering on specification breach

Modernising ERP for Manufacturing

Migrate from legacy on-premise ERP to SAP S/4HANA or Dynamics 365 Manufacturing with zero data loss
Build custom manufacturing-specific modules for BOM versioning, by-product costing, and tooling management
Integrate ERP with MES, QMS, and IIoT platforms for a fully connected digital manufacturing backbone
Train super-users and deploy change management programme to drive adoption across shifts and sites

Why Bluejay

Why Choose Bluejay for Manufacturing?

Industry 4.0 Engineering Depth

Our team includes IIoT architects, control-systems engineers, and ML specialists who have deployed smart factory systems in automotive, aerospace, food & beverage, and electronics manufacturing.

OT/IT Integration Expertise

We bridge the gap between operational technology (PLCs, SCADA, DCS) and IT systems (ERP, cloud, analytics) using industrial protocols and secure edge computing architecture.

Proven AI for Industrial Use

Our predictive maintenance and computer vision models are production-tested in environments with strict safety and traceability requirements, not just proof-of-concept demos.

Scalable from Pilot to Enterprise

We design pilots to be production-ready from the start — architecture decisions that let you expand from one line to ten plants without re-engineering the platform.

Tech Stack