Software development for manufacturing. From consulting to operations.
We consult first. Then we build exactly what your operation needs – and run it for you if you wish. IT consulting, bespoke development, AI solutions and operations come from one team – digital solutions for manufacturing in which no stage is handed over to third parties.
- OPC UAPlant and machine data
- PLC/S7Controllers
- MQTTSensors and IIoT
- MES/ERPOperational and order data
- PDF/OCRTechnical documents
- EU hostingor on-premise at your plant
Four services in detail.
Each service has its own page with our approach, typical tasks and answers to the questions that are usually still open before a project.
Custom software development
Every company works differently, and standard software rarely covers that completely. We develop bespoke software that fits your workflows, your staff and your system landscape – straightforward to use and extensible later on.More on custom software developmentAI solutions for businesses
Want to use AI but unsure where it makes sense in your operation? We look at your processes, name the cases where AI helps, and develop a solution that backs every output with its source and a confidence score.More on AI solutions for businessesProcess automation
Many tasks are still done by hand every day – that costs time and leads to errors. With process automation, recurring workflows run automatically: we connect your systems, simplify procedures and take load off your team.More on process automationData visualisation & dashboards
Is your data spread across programs, machines and files? We bring it together and show states and key figures in one clear dashboard – so you see machine and plant data at a glance and decide faster.More on data visualisation
Understand first, then decide.
We clarify which data you have, what it is worth and what can be implemented with reasonable effort.
We do not start with software but with an inventory: which data is generated in your plants, machines and documents, where does it sit today and who works with it? From this we develop a data strategy with you that names goals, data sources and responsibilities.
For specific initiatives we prepare a feasibility study using your own data – not sample data. You receive a reliable assessment of data quality, effort and expected benefit, together with a target architecture that fits the PLCs, OPC UA, MES and ERP in your plant.
The consulting phase ends with a recommendation and a quotation – at a fixed price or on a time-and-materials basis. Whether and with whom you implement is your decision.
- Inventory of data, systems and processes
- Data strategy with goals and priorities
- Feasibility study using your data
- Target architecture and interface concept
- Effort estimate and quotation
- Typical duration
- 2–5 days
Example scenario
A supplier with three production lines wants to know whether downtimes can be predicted from existing controller data. In a two-day workshop we would review the OPC UA signals and the maintenance history, check the data quality and determine which line is suitable for a pilot.
Custom software that fits your system landscape.
We develop applications and interfaces that connect to what is already running in your operation.
Standard software rarely covers an operation completely. We build the applications that are missing: interfaces to PLCs, OPC UA, MES and ERP, data pipelines that bring signals and records together, process automation for recurring workflows between these systems, and web applications and dashboards that visualise data for the control room, maintenance and quality.
Work is organised in two-week cycles. Every cycle ends with a running version that you test with your data and accept. Requirements may change – the current state is visible at all times.
The source code belongs to you. We document architecture, interfaces and operations so that your IT department or a third party can take over the solution.
- Interfaces to PLCs, OPC UA, MES and ERP
- Data pipelines and data models
- Web applications and dashboards
- Automated tests and acceptance per cycle
- Documentation and source code handover
- Typical duration
- 2-week cycles
Example scenario
A machine builder records order progress on paper and transfers it to the ERP system in the evening. We would connect the controllers via OPC UA, merge machine and order data in one pipeline and provide the control room with a dashboard – the ERP reconciliation would then run automatically.
AI for documents, anomalies and processes.
Models that work on your data and back every output with its source and a confidence score.
We apply AI where its effect can be measured: to technical documents that become searchable and analysable – manuals, datasheets, maintenance reports and standards; to plant and machine data in which anomalies are detected early; and to processes whose bottlenecks become visible from throughput and order data.
Every extraction and every anomaly comes with its source and a confidence score. You see why the system suggests something and decide for yourself what follows. Your data is not used to train third-party models.
The entry point is a pilot with your own documents or signals. Only when the results meet the agreed criteria does the rollout follow – built on ralwo PlantPulse, ralwo DocIntel and ralwo FlowOptimizer or as an individual development.
- Document analysis with OCR, extraction and question answering
- Anomaly detection on sensor and controller data
- Process and bottleneck analysis
- Traceable outputs with source and confidence
- Pilot with your data and agreed criteria
- Typical duration
- 1–2 weeks to the pilot
Example scenario
The maintenance department of a plant operator searches for torque values, intervals and spare part numbers across several thousand PDF pages. We would set up a pilot on a subset of the documents, check the hit rate against manually recorded values and only then decide which archives are indexed in full.
Operations in the EU or at your plant.
We run the solution if you wish – with monitoring, support and training for your staff.
A solution is only finished once it runs reliably. We operate it on servers in the EU or on-premise at your plant, monitor availability, data flows and model quality, and roll out updates in agreed maintenance windows.
Support and response times are set out in an SLA that matches your shift pattern. We train your staff on the live application – users, key users and administrators separately.
If you prefer to take over operations yourself, we hand over in an orderly way: documentation, access credentials, runbooks and a supported transition phase.
- Hosting in the EU or on-premise
- Monitoring of availability, data flows and model quality
- Maintenance, updates and security patches
- Support with an agreed SLA
- Training and orderly handover
- Typical duration
- ongoing
Example scenario
A mid-sized company running two shifts wants to operate its plant monitoring in its own data centre. We would monitor the data connection remotely, respond within agreed times and train new shift supervisors on the live application.
From the initial consultation to operation.
Four phases with clear time frames. After each phase you decide whether and how to continue.
01 Free initial consultation
approx. 30 minWe clarify goals, data situation and feasibility – by phone or video call.
- Goals and the question at hand
- Data situation and existing systems
- Feasibility and next steps
02 Analysis & concept
1–2 weeksWe review your data sources, design the architecture and submit a proposal.
- Data sources and interfaces
- Architecture and data flow
- Proposal at a fixed price or time and materials
03 Implementation
2-week cyclesWe develop in short cycles, integrate with your existing systems and test with your data.
- Integration with PLC, MES and ERP
- Tests with your data
- Acceptance after every cycle
04 Operation & development
ongoingWe run the solution if you wish, and develop it further together with your operation.
- Monitoring and maintenance
- Support and training
- Further development as required
Every phase ends with a decision that you make.
Frequently asked questions about our services.
What is usually clarified before an engagement – answered briefly. Everything else we discuss in the free initial consultation.
Free · No obligation · approx. 30 minutes
Let’s talk about your plant.
In a free initial consultation we clarify your goals, your data situation and the feasibility – with no obligation.