CodeXcelerate
CodeXcelerate
// Manufacturing software development
Manufacturing software operates in an environment that breaks general-purpose software patterns: intermittent connectivity on the factory floor, ruggedised devices with limited screen real estate, shift workers with no tolerance for UX complexity, high-volume IoT sensor data that must be processed in near-real-time, and integration requirements with ERP and MES systems that are notoriously difficult to connect to modern software. CodeXcelerate builds custom manufacturing software — IoT production dashboards, MES/ERP integrations, AI quality inspection systems, predictive maintenance tools and digital work instruction platforms — for manufacturing companies across the US, UK and Australia. We design for the factory floor, not the boardroom demo.
15+
Operational tech projects
ISO 9001
Process context
$5K
Starting from
8–14 wks
Typical delivery
// what we build
Real-time production dashboards aggregating IoT sensor data — machine OEE (Overall Equipment Effectiveness), throughput rates, temperature, pressure, vibration, cycle time and energy consumption — with configurable threshold alerting and historical trend analysis. Web and tablet-optimised for factory floor use. Supports MQTT, OPC-UA, Modbus and HTTP-based sensor protocols across diverse industrial equipment.
Computer vision quality inspection systems trained on your production imagery — surface defect detection, dimensional deviation analysis, assembly error identification and anomaly classification at line speed. Integrated with your production line via PLC triggers or camera positioning systems. Designed for human-in-the-loop validation: the AI flags and classifies, human inspectors make the final call on ambiguous cases, and the system improves from every correction.
ML-based predictive maintenance systems that analyse machine sensor data — vibration, temperature, acoustic signatures, power draw — to predict failure events before they cause unplanned downtime. Work order generation triggers automatically when a machine crosses a predicted failure threshold, dispatching the right maintenance team with the right parts. Integrates with CMMS (Computerised Maintenance Management Systems) like SAP PM, Maximo or custom systems.
Mobile-first digital work instruction platforms replacing paper-based procedures with interactive, version-controlled digital guides — step-by-step instructions with images and video, quality checkpoints, electronic sign-off and deviation capture. Offline-first architecture for factory floors with poor connectivity. Role-based access: operators see their station's instructions; supervisors see completion status across the line; quality managers see deviation history.
Custom integration between your production systems and SAP, Oracle, Microsoft Dynamics or custom ERP/MES platforms — bidirectional data sync for production orders, inventory movements, quality data, BOM consumption and cost reporting. We handle the complex data mapping, transformation and error handling that ERP integration always requires, including the edge cases (partial posting failures, duplicate order IDs, schema drift between ERP versions) that surface only in production.
End-to-end supply chain tracking platforms — supplier onboarding portals, purchase order management, shipment tracking integration (carrier APIs, EDI 856 ASN), goods receipt workflows, inventory visibility across multiple warehouses and demand forecasting dashboards. Real-time supplier performance scorecards and automated exception alerting when shipments are delayed or quality holds are raised.
Advanced production scheduling tools that optimise job routing across work centres, manage capacity constraints, handle machine downtime replanning and provide shop floor supervisors with real-time schedule adherence visibility. Integration with your ERP's production planning module or as a standalone APS (Advanced Planning and Scheduling) layer over an existing MES. Drag-and-drop Gantt chart interface for manual override when production conditions change.
Real-time asset tracking systems using RFID, BLE beacons or QR codes — tracking tools, fixtures, WIP inventory, finished goods and returnable containers across your facility. Mobile app for asset check-out, check-in and location lookup. Integration with your ERP for asset valuation and maintenance scheduling. Significantly reduces time spent searching for tools and misplaced inventory.
// compliance & standards
ISO 9001:2015
Quality management system requirements — document control, non-conformance tracking, CAPA (Corrective and Preventive Action) workflows and management review data pipelines built into the quality inspection and work instruction systems.
OPC-UA / MQTT / Modbus
Industrial communication protocol support for connecting diverse PLCs, SCADA systems and sensors — OPC-UA for modern industrial equipment, MQTT for IoT-over-IP devices, Modbus RTU/TCP for legacy industrial controllers.
ISO 27001
Information security management for manufacturing data systems — particularly important for OT/IT convergence where factory floor networks connect to enterprise systems carrying IP-sensitive production data.
GMP (for pharma/food manufacturing)
Good Manufacturing Practice compliance for 21 CFR Part 11 electronic records and signatures, audit trails for regulated manufacturing environments (pharmaceutical, medical device, food production).
// how we work
01
We visit your facility (or run structured remote workshops) to map production workflows, machine types and protocols, connectivity conditions and user roles before writing a line of code. Manufacturing projects fail when software is designed for a boardroom, not for a person in PPE on a noisy production line. We observe the actual environment.
02
Factory software sits at the intersection of Operational Technology (PLC, SCADA, sensors) and Information Technology (ERP, databases, cloud). We design the architecture to bridge both safely — network segmentation, data buffering for connectivity dropouts, protocol translation layers and security boundaries between the OT network and enterprise systems.
03
ERP and MES integration is the highest-complexity element in most manufacturing software projects. We scope this separately from application development — mapping your ERP's specific API capabilities, identifying which data exchanges require real-time vs. batch sync, and building the integration layer in parallel with the application UI to avoid blocking the build phase.
04
We develop in two-week sprints with weekly demos, and plan at least one factory pilot session before the final delivery sprint — deploying a working version of the software on the actual factory floor (or a dedicated test station) to catch usability and connectivity issues before they affect the production launch.
05
Manufacturing software requires Factory Acceptance Testing against real production conditions — real sensor data volumes, real connectivity interruptions, real users in PPE on factory devices. We structure a formal FAT phase with your quality and production teams to sign off on each functional requirement before go-live.
06
We recommend a phased go-live starting with one production line or work centre before rolling out plant-wide — reducing the blast radius of any issues discovered in the first weeks. We provide on-site or remote support during the initial production period, with a dedicated escalation channel for production-critical issues.
// the complexity
Factory floor connectivity is intermittent — software that requires stable internet is a liability; offline-first architecture is required
OT/IT integration requires bridging disparate protocols (OPC-UA, MQTT, Modbus) that most web agencies have never implemented
ERP integration with SAP or Oracle is notoriously complex — real production data has edge cases the ERP documentation doesn't mention
Manufacturing UX must work for users in PPE on ruggedised devices with gloves — standard touchscreen UX assumptions break down
AI quality inspection accuracy must exceed human inspection baseline before operators trust and adopt it — model training data quality is critical
// tech stack
// transparent pricing
India-based senior engineers — typically 60–70% less than a comparable US or UK agency for equivalent experience.
| What You're Building | Investment Range | Timeline |
|---|---|---|
| IoT production dashboard (5–20 machines) | $5,000 – $15,000 | 5–8 weeks |
| AI quality inspection system | $6,000 – $18,000 | 6–12 weeks |
| Predictive maintenance platform | $8,000 – $20,000 | 8–14 weeks |
| Digital work instructions (plant-wide) | $5,000 – $12,000 | 5–8 weeks |
| ERP/MES integration (bidirectional) | $5,000 – $15,000 | 4–10 weeks |
| Full MES-adjacent platform (IoT + quality + ERP) | $20,000 – $60,000+ | 16–28 weeks |
Ranges are guidance based on typical scope. A free technical call gives you a precise fixed-price quote for your specific requirements.
// outcomes
// faq
Manufacturing software development with CodeXcelerate costs from $5,000 for a focused IoT dashboard or digital work instruction system up to $60,000+ for a full MES-adjacent platform combining IoT, AI quality inspection and ERP integration. An IoT production dashboard for 5–20 machines starts at $5,000–$15,000. AI quality inspection runs $6,000–$18,000. A full platform with IoT, quality and ERP integration costs $20,000–$60,000+. At our India-based rates, you pay 60–70% less than a comparable UK or US manufacturing software firm.
// let's build
Free 30-minute technical call. We map your requirements, give you a realistic scope and cost, and tell you honestly if we're the right fit.
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