# Manufacturing & Industry 4.0 > Shop-floor dashboards, machine vision quality inspection, and predictive maintenance for connected factories. Provider: Netstatic Solutions (https://www.netstatic.in/) Page: https://www.netstatic.in/domains/manufacturing-industry-4-0 Email: netstaticsolutions@gmail.com ## Overview Manufacturers are under pressure to raise quality, reduce downtime and respond faster to demand. Much of the data needed to do this already exists in machines, sensors and ERP systems, yet it is rarely joined up in a form that supervisors and managers can act on. Netstatic Solutions builds industrial software that connects the shop floor to decision makers. We deliver production dashboards, machine vision inspection, predictive maintenance models and integrations between PLCs, SCADA, MES and ERP, giving teams timely and trustworthy operational information. We understand that factory software must be dependable and clear to use on the line. Our engineering considers network constraints, edge processing, safe rollout and security practices informed by standards such as IEC 62443 and ISO 27001, with minimal disruption to running production. ## Industry challenges - **Unplanned machine downtime:** Breakdowns halt production and disrupt schedules, and calendar-based maintenance either services equipment too early or misses developing faults. - **Manual quality inspection:** Human inspection is slow and inconsistent across shifts, so defects can reach customers while good parts are rejected. - **Disconnected shop-floor data:** Machine, MES and ERP data sits in separate systems, so managers rely on delayed manual reports to understand output and losses. - **Legacy equipment:** Older machines use varied protocols and lack connectivity, making data collection a custom integration challenge for every line. ## What we build - **Machine vision quality control:** Camera-based inspection using computer vision to detect surface defects, missing parts and dimensional deviations on the line, with images stored for traceability and review and documented clearly for your team. - **Predictive maintenance models:** Models trained on vibration, temperature and runtime signals that flag abnormal behaviour early, helping maintenance teams plan interventions before failures occur and documented clearly for your team. - **Production and OEE dashboards:** Live dashboards for output, downtime reasons, shift performance and OEE, designed for large displays and tablets so supervisors can respond during the shift and documented clearly for your team. - **IoT and edge connectivity:** Gateways and services that collect data from PLCs and sensors using protocols such as OPC UA and MQTT, with local buffering when connectivity drops and documented clearly for your team. - **MES and ERP integration:** Connectors that synchronise work orders, material consumption and completion data between the shop floor and ERP, reducing double entry and reporting delays and documented clearly for your team. - **Desktop and tablet operator apps:** Focused operator interfaces for work instructions, checklists and issue reporting, designed for gloves, glare and fast use at the workstation and documented clearly for your team. ## Use cases - **Automated defect detection:** A components maker inspects every part with cameras and routes flagged items to a manual review station. - **Motor health monitoring:** A plant monitors vibration on critical motors and receives alerts when readings trend away from normal. - **Real-time OEE visibility:** A multi-line factory replaces paper logs with live availability, performance and quality views per machine. - **Digital work instructions:** An assembly unit gives operators step-by-step guided instructions with required checks and recorded sign-offs. ## Standards we design for - IEC 62443 - ISO 9001 - ISO 27001 - OPC UA - ISA-95 ## Services we apply - [Image Processing & CV](https://www.netstatic.in/services/image-processing-computer-vision.md): Advanced computer vision, automated image recognition, and custom visual data analysis pipelines. - [AI Development](https://www.netstatic.in/services/ai-development.md): Building custom AI models, LLMs, and automated intelligent workflows tailored to your business needs. - [Desktop App Development](https://www.netstatic.in/services/desktop-app-development.md): High-performance, resource-efficient desktop applications for Windows, macOS, and Linux operating systems. - [Cloud Infrastructure](https://www.netstatic.in/services/cloud-infrastructure.md): Architecting resilient cloud systems, serverless deployments, and secure scalable data operations. ## FAQ **Can you connect our older machines?** Often yes. We use PLC protocols, serial interfaces, retrofit sensors and edge gateways to extract data from older equipment. A site assessment determines what each machine exposes, so we can recommend a practical and low-risk connection approach. **How accurate is machine vision inspection?** Accuracy depends on lighting, camera placement, defect type and the quality of training images. We run a pilot on your real parts, measure results against your criteria and tune before rollout, rather than promising a fixed figure upfront. **Will this disrupt production during rollout?** We plan phased deployment starting with one line or station, running new systems alongside existing processes first. Edge components are designed to work through short network interruptions, so production does not depend on cloud connectivity. **Do you integrate with SAP or other ERP systems?** We integrate with major ERP and MES platforms through their APIs, database interfaces or middleware, depending on what is available. We map data fields and ownership carefully with your IT team so shop-floor and business records stay consistent.