The Foundations & the Disconnect

The Three Pillars of Modern Manufacturing

Manufacturing × ERP

Improve your production planning, resource division, and supply chain management with our manufacturing x ERP solutions. Manage workflows and increase the overall efficiency of your business operations.

SMART INTEGRATION APPS

APPS Beyond raw data, these applications analyze trends, detect anomalies, andturn machine events into actionable guidance.

ENTERPRISE RESOURCE PLANNING (ERP)

The IT backbone, here ERP’s such as Odoo, SAP etc manages scheduling, Work Orders, inventory, maintenance planning, financials and other managerial tasks.

The Disconnect

Problem

When Operational Technology (OT), smart integration apps, and ERP systems operate
in silos,manufacturers face far more than just machine downtime. The lack of integration leads to

REACTIVE OPERATIONS

  • Problems like failed power supplies are only addressed after breakdowns, causing major downtime and financial loss.
  • Teams respond late because machine data isn’t connected to maintenance planning or inventory systems.

    • DATA SILOS & INCONSISTENT REPORTING

  • Critical data is scattered across spreadsheets, dashboards, and systems thatdon’t talk to each other.
  • Employees waste time collecting and cleaning data instead of making decisions.
  • Inconsistent reports between departments create confusion and delays.

    • POOR TRACEABILITY & QUALITY CONTROL

  • Without full product and process traceability, recalls and audits become slow,manual, and error-prone.
  • Quality data may be paper-based or isolated, making root cause analysisdifficult and increasing scrap.

    • INEFFICIENT INVENTORY & PLANNING

  • ERP systems can’t react to real-time shop-floor activity, leading to overstock, low or no Stock and bottlenecks.
  • Schedulers lack accurate data on machine capacity and material status, causing production delays and overtime.

    • DATA SILOS & INCONSISTENT REPORTING

  • ERP systems can’t react to real-time shop-floor activity, leading to overstock, low or no Stock and bottlenecks.
  • Schedulers lack accurate data on machine capacity and material status, causing production delays and overtime.

    • SLOW, REACTIVE DECISION-MAKING

  • Executives and planners struggle to get timely insights.
  • Companies lose agility, fall behind on delivery goals, and miss out on market opportunities.

    • Irondevs solves this by integrating Weidmuller OT devices with smart analytics and Odoo ERP, creating a connected ecosystem that delivers real-time insights, automates decision-making,and empowers every level of your business from the shop floor to the boardroom.

    OUR APPROACH

    Irondevsxerp bridges all three pillars by:

    Layering “Smart Integration Apps” to Weidmuller’s OT Hardware that provide:
  • ProSight for production monitoring
  • HealthTrack for machine-condition analytics
  • Preventive Maintenance for failure prediction (Replace an end of life device before it fails)
  • Optimal Process Flow for workflow optimization
    • Seamlessly Connecting to Odoo ERP, enabling:
  • Bi-directional data flow of production orders, parts, and maintenance tasks
  • Real-time updates of capacity, inventory, scheduling, accounting and more!

    • WHY THIS MATTERS

    Faster Problem Detection & Response
  • You see issues like machine slowdowns or failures as they happen, not after production stops.
    • Less Downtime
  • Maintenance teams get early warnings so they can fix issues before something breaks.
    • Better Production Planning
  • Real-time data helps managers make accurate schedules and avoid overloading machines or workers.
    • Smarter Inventory Control
  • You always know what materials are being used and what’s running low no more surprise shortages or overstocking.
    • Improved On-Time Delivery
  • With live updates from the floor and ERP, teams can adjust quickly to stay on schedule.
    • Clearer Team Communication
  • Everyone from operators to executives uses the same, up-to-date information to make decisions.
    • Easier Quality Tracking
  • You can trace exactly which materials and machines were used in every product, making audits and recalls simple.
    • Less Manual Work
  • No more entering the same data into multiple systems. Everything updates automatically.
    • Faster, Smarter Decisions
  • With accurate data flowing across all systems, leaders make quicker and more confident decisions.
    • Higher Profit Margins
  • Less waste, better efficiency, and fewer delays mean lower costs and better use of resources.

    • KEY SOLUTIONS

    ProSight: Real-Time Production Monitoring
  • Automatic tracking of machine performance & Utilization Tracking without manual entry
  • Downtime Root-Cause Analysis using historical trends and live updates
  • KPI Dashboards & Alerts for instant shop-floor visibility
    • HealthTrack: Live Machine-Condition Monitoring
  • PLC & Sensor Data Collection from any machine
  • Visual Diagnostics & Alarm Analytics to spot anomalies
  • Remote Service & Workflow-Driven Alerts for timely maintenance
    • Preventive Maintenance: Predict & Prevent Failures
  • Real-Time Condition Thresholds trigger maintenance before breakdowns
  • Failure Mode Identification Finds what went wrong and why
  • Automated Computerized Maintenance Management for work-order creation
    • Optimal Process Flow: Continuous Improvement
  • Bottleneck & Cycle-Time Analytics to pinpoint inefficiencies
  • Operator Feedback & Workflow Builder to deliver step-by-step instructions
  • Changeover, Setup & Scheduling Optimization integrated with ERP
    • Get Started
    OT X IronDevs
    Pro Sight
    Health Track
    Contact Us