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IT SERVICES FOR MANUFACTURING

Developing smart, scalable and secure digital systems for Modern Manufacturing Plants.

We deliver IT services for manufacturing that connect machines, people and data across shop floors and enterprise systems.

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IT services for manufacturing

Custom Manufacturing Software Solutions We Deliver

At Prodgrade we provide it services for manufacturing that streamline production, raise OEE and shorten time to value. Our teams build interoperable platforms that fit plant realities like variable cycle times, mixed equipment and strict change control. Whether you are launching a greenfield line or modernizing legacy assets, we design secure, scalable software that supports continuous improvement across operations and makes data useful for every role.

Manufacturing Execution Software (MES)

Track orders, work in process and quality events in real time. Enforce routing, electronic work instructions, nonconformance handling and genealogy while feeding trusted data to ERP and manufacturing analytics.

Machine Monitoring System

Collect high frequency signals from CNCs, PLCs and sensors to visualize utilization, downtime and scrap. Get alerts on deviation, bottlenecks and energy spikes with root cause data attached for real time monitoring of manufacturing equipment.

Production Schedule Software

Plan finite capacity, sequence jobs, simulate what if and publish schedules to stations. Balance constraints across tooling, skills and changeovers to reduce idle time and overtime with clear dispatch lists.

Equipment Management Software

Manage assets, PM calendars, spare parts and calibration. Trigger maintenance from runtime thresholds or condition signals to prevent unplanned stops and extend useful life.

Manufacturing Data Analytics

Unify historian, MES and ERP data into trusted models. Build dashboards for OEE, first pass yield and cycle adherence with drill downs from plant to line to machine that turn metrics into action.

Traceability and Electronic Batch Records

Record material lineage, operator actions and parameter windows. Generate audit ready history for regulated environments and high value lots so investigations finish faster.

Quality Management and SPC

Capture in process checks, automate control charts and trigger containment when limits drift. Integration with CAPA and supplier feedback loops to protect yield and customer trust.

Warehouse and Intralogistics

Digitize receiving, putaway, kitting and line side delivery. Use scans and IoT to keep components synchronized with takt and remove manual status calls.

Supplier and Customer Portals

Share forecasts, ASN and quality alerts. Give customers secure order status, certificates and traceability records so partners see the same truth you do. Our approach to it solutions for manufacturing favors standards based connectivity, modular services and analytics that spotlight the next best improvement.

Who We Serve in the Manufacturing Ecosystem

Discrete Manufacturers

Process Manufacturers

High-Tech Assembly Plants

Pharma Producers

Contract Manufacturers

Tiered Supplier Networks

Global Plant Groups

Greenfield Factories

Industrial Automation

Smart Manufacturing

Our Manufacturing Software Development Process

manufacturing software solutions
Discovery and Planning

We map value streams, constraints and target KPIs with production, maintenance, quality and IT. The output is a clear backlog tied to outcomes like OEE lift, faster changeovers or scrap reduction, plus a realistic plan to reach them.

We design an ISA 95 aware blueprint that separates enterprise and control domains, defines data models and secures interfaces. Wireframes reflect station realities like gloves, glare and downtime codes so operators can use them without friction.

We deliver in sprints with line-focused increments. Early pilots prove connectivity, UX and performance on the floor before we scale across shifts or sites, so adoption feels natural.

We connect PLCs, CNCs and sensors through OPC UA or MTConnect for normalized telemetry, then sync with ERP, PLM and CMMS through secure APIs. Nothing brittle, everything traceable.

We run functional, performance and resilience tests including offline scenarios at the edge. UAT happens at real stations with operators across shifts so sign off reflects day to day use.

Rollouts follow change windows and rollback plans with clear operator training. CI and CD automate promotion from test cells to production, so updates are routine, not risky.

After go live we watch stability, track adoption, tune dashboards and expand features that move the KPIs you care about most. Small wins stack into big gains.

Security and Compliance at Every Step

  • Defense in depth for IT and OT, with network segmentation, least privilege and encrypted data in transit and at rest.
  • Alignment with the NIST Cybersecurity Framework Manufacturing Profile for risk based controls across assets, detection and response.
  • Architecture mapped to ISA 95 boundaries to reduce lateral movement and clarify data exchange between enterprise and control systems.
  • ISO 9001 ready records for process control, change management and audit trails.
  • Role based access, MFA and tamper evident logs for operators, technicians and engineers.
  • Secure remote access with session recording for vendors and service partners.
  • Regular vulnerability scans, dependency checks and penetration tests in plant aware windows.
  • Cloud security baselines for AWS, Azure and GCP with backups and disaster recovery plans.

These practices cut cybersecurity exposure, support quality certifications and keep production safe from disruption.

Third-Party Integrations We Support

  • Enterprise Resource Planning (ERP): SAP, Oracle, Microsoft Dynamics
  • PLM and CAD: Teamcenter, Windchill, 3DEXPERIENCE
  • Historians and SCADA: OSIsoft PI, AVEVA, Ignition
  • CMMS and EAM: IBM Maximo, SAP EAM, ServiceNow
  • QMS and LIMS for regulated plants
  • Cloud platforms: AWS, Azure, Google Cloud
  • Identity and SSO: Azure AD, Okta
  • Messaging and streaming: MQTT, Kafka
  • Machine connectivity: OPC UA servers and clients, MTConnect agents and adapters

Why Prodgrade is Your Ideal Development Partner

Choosing a partner shapes how your platform runs, scales and stays safe. We pair finance know how with careful engineering and plain language, so decisions are quicker and progress is easier to see.

Manufacture Industry Experts

Our engineers work on the floor with operations, maintenance and quality. We design gloves, noise and real downtime codes.

Scalable, Custom-Built Solutions

We deliver custom solutions that respect ISA 95, OPC UA and MTConnect so you avoid lock in and scale across vendors.

Outcome Focused

We attach every feature to a KPI like OEE, FPY or schedule adherence. Releases ship when they move a metric.

Agile and Transparent Process

You see roadmaps, demos and telemetry. Decisions are made with data from the floor, not slides.

Long Term Support and Upgrades

We stay to operate, tune and extend so the platform keeps earning its place. Roadmaps are real, not wish lists.

Security and Compliance First

Architectures align with the NIST manufacturing profile and ISO 9001 expectations for documented processes and audits.

Scale with Confidence

We start with a pilot cell, harden at one line, then template across sites with automated deployment.

Other Industries We Work With

While we specialize in IT services for manufacturing, our teams also build reliable platforms for other industries as well. Here are some industries:

Healthcare

Building intelligent, AI-powered solutions for better healthcare delivery.

Explore more

Education

Transforming learning experiences through AI to support students and modern classrooms.

Explore more

Logistics

Simplify supply chain operations with smart platforms that improve tracking, reduce costs & ensure smooth delivery flows.

Explore more

Travel and Hospitality

Enhancing guest journeys through AI-driven personalization, smart bookings, and seamless service.

Explore more

Telecommunication

Streamlining telecom operations with AI for smarter networks, uptime, and customer support.

Explore more

Banking

Empowering banks with AI solutions for fraud detection, risk insights, and customer trust.

Explore more

Retail

Driving smarter retail with AI-powered tools for personalization, inventory, and customer loyalty.

Explore more
View All Industries

Cost and Timeline of Financial Software Solutions

The development cost and delivery timeline for manufacturing software depend on scope, plant complexity, integration depth and validation needs. Below is a breakdown of estimated investments and schedules for common solutions we deliver. The goal is clear, match your budget, shorten time to value and keep rollout risk low.

Manufacturing Execution Software (MES)

Coordinate orders, work in process and station data with live updates across lines.

Estimated Cost: $120,000 – $240,000
Timeline: 6 to 10 months


Key Features:

  • Routing and enforcement
  • Electronic work instructions and data capture
  • Nonconformance and rework management
  • Genealogy and full traceability
  • ERP and historian integration

Machine Monitoring System

Collect utilization, alarms and part counts from diverse assets with real time insight.

Estimated Cost: $60,000 – $130,000
Timeline: 3 to 6 months


Key Features:

  • Connectivity via OPC UA or MTConnect
  • Downtime codes and escalation
  • Condition and energy signals
  • Alerting with mobile notifications
  • OEE and performance dashboards

Production Schedule Software

Plan finite capacity, sequence jobs and publish dispatch lists to the floor.

Estimated Cost: $70,000 – $140,000
Timeline: 4 to 7 months

Key Features:

  • Constraint based scheduling
  • Setup and changeover logic
  • What if simulation
  • Feedback loop to MES and machines
  • Adherence and on time metrics

Equipment Management Software

Control maintenance plans, spares and calibration to protect uptime.

Estimated Cost: $55,000 – $110,000
Timeline: 3 to 5 months


Key Features:

  • Asset registry and PM calendar
  • Runtime or condition triggers
  • Work orders with parts usage
  • Vendor and service records
  • Downtime analysis and MTBF

Manufacturing Data Analytics

Unify plant data for trusted KPIs and drill downs from site to cell.

Estimated Cost: $50,000 – $100,000
Timeline: 3 to 5 months


Key Features:

  • OEE and first pass yield
  • Cycle adherence and bottleneck views
  • Scrap and cost per unit tracking
  • Self-service dashboards
  • Data lake or warehouse models

Quality Management and SPC

Detect drift early and enforce containment with audit ready records.

Estimated Cost: $55,000 – $120,000
Timeline: 3 to 6 months


Key Features:

  • In process checks and eSignatures
  • Control charts with rules
  • CAPA workflows
  • Supplier quality feedback
  • Certificates and compliance logs

Traceability and Electronic Batch Records

Capture material lineage and operator actions for regulated or high value lots.

Estimated Cost: $65,000 – $130,000
Timeline: 4 to 7 months


Key Features:

  • Lot and serial tracking
  • Parameter windows and limits
  • Structured eBR with approvals
  • Hold, release and disposition
  • Audit reporting and exports

Supplier and Customer Portals

Share forecasts, ASN, quality alerts and order status securely.

Estimated Cost: $45,000 – $95,000
Timeline: 3 to 5 months


Key Features:

  • Role based dashboards
  • Document exchange and alerts
  • Claims and disposition flows
  • Delivery and receipt visibility
  • Audit trails with exports

NEED A CUSTOM QUOTE?

Every plant has unique constraints and goals. Tell us about your products, lines and KPIs so we can provide a precise estimate that fits your timeline and budget.

Get a Quote

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Frequently Asked Questions

What is the difference between MES and ERP for manufacturers?

ERP plans and accounts for resources across the business while MES runs the shift by capturing execution on the floor. Many plants integrate both so orders and inventory flow down and actuals flow up.

Yes. We use gateways, PLC taps and standards like OPC UA and MTConnect to normalize signals without changing the machine control. This reduces custom drivers and speeds rollout.

We segment networks, enforce least privilege, use encrypted channels and align to the NIST manufacturing profile. Access is role based with MFA and audit trails.

Yes. Our edge gateways buffer data onsite, publish events to the cloud and keep dashboards responsive even with variable connectivity.

We record electronic signatures, changes and genealogy. Reports and logs support ISO 9001 quality system audits.

We design to ISA 95 boundaries, use OPC UA for interoperability and MTConnect where machine tools are present so you can scale across vendors and sites.

Most clients begin with a focused pilot in one cell or line and see measurable improvements within eight to twelve weeks. We then template across lines and sites.

Yes. We ingest historian data, model KPIs and publish to tools like Power BI while keeping time series detail for engineers.

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