Manufacturing & Industrial
We find out whether your plant networks, control systems, workstations and supplier connections are safe from attackers, and fix what we find. Factories lose money when machines stop and when software gets in the way. We connect machines to live data, replace outdated systems with software you own, and secure the factory network.
Manufacturers depend on equipment that runs around the clock and on software that was often bought years ago and never fitted to the plant. When a machine drifts out of tolerance or a product reaches its end of life, the cost shows up as scrap, downtime and manual rework.
We moved a textile weaving company from five outdated products to one custom platform fed by sensors on its machines. The method carries over to other plants: start with the data the machines can give you, then build the software around it.
What we see in your industry
- Machines run without live monitoring, so problems are found when production stops.
- Several outdated products for ERP, machine management and reporting each hold part of the picture.
- Factory-floor equipment and office IT share networks that were never designed to be separated or defended.
- Planners want AI for forecasting and reporting that runs on production data kept inside the plant's own systems.
Machine monitoring starts with sensors. Low-cost computers such as Raspberry Pi, paired with temperature, humidity and vibration sensors in industrial enclosures, can feed live dashboards and alerts, so a maintenance team sees a problem developing instead of finding out when the line stops. We design the hardware, the installation and the software together.
Legacy software is the second problem. When ERP, machine management and reporting live in separate products, people re-enter data between them and nobody trusts a single number. A custom platform replaces them with one system built for how the plant works, owned by the company and extended as needs change.
Operational technology (OT) and IT security belong in the same plan. Connecting machines to the network exposes them, so we segment the factory floor from office systems, manage the devices and test the result the way an attacker would. Cyber automation and private AI then use the same data for scheduling, quality checks and reporting, without sending production data to public services.
The weaving factory is the proof. The first prototype ran in two weeks, the full platform followed in three months, and the company reports savings in the millions of dollars within a year. The same path fits other plants: prototype with real sensors, show the numbers to the people on the floor, and extend from what they use.
For the security half of the plan, read "OT and ICS Security for Manufacturers," which applies NIST SP 800-82 Rev. 3 and CISA guidance to a plant, and "Replacing Legacy Business Software with Custom Software" for the software half.
Every industry's reference library and routine can run offline. Our Apocalypse IT Package is an on-premises continuity kit with a local reference library, document scanning, a private AI desk, chat and battery backup, offered to every customer.
Related work on our track record: private 5G on CBRS spectrum for a Tier-1 auto plant (illustrative), the textile weaving factory with Raspberry Pi monitoring, a multinational's separated regional networks across 14 countries (illustrative), and a logistics ERP tied to warehouse sensors over MQTT and OPC UA.
OT and ICS Security for Manufacturers: A Practical Guide Based on NIST SP 800-82 Rev. 3 and CISA Guidance
Plant-floor systems were built for uptime and safety, not for the internet. NIST SP 800-82 Rev. 3 and CISA's 2025 joint guidance give manufacturers a clear order of work: get controllers off the internet, change default passwords, lock down remote access, separate IT from OT, and keep the ability to run by hand.
Work like yours
One company in fourteen countries, with separate networks by region and business unit and zero downtime
A multinational manufacturer and distributor operating in 14 countries, a leader in its segment.
14 countries, 4 regions, 6 business units, 9 datacenter and carrier-neutral facilities, 10G to 100G fabricsRead the case
A weaving factory got its own software and live data from every machine
A textile weaving company, a leader in its segment, running five separate, outdated software products (ERP, machine management and more) with no live monitoring of its machines.
5 legacy products replaced by 1 custom platform, every machine, real-time sensorsRead the case
An ERP and a warehouse that talk to each other: robots, sensors and software on one platform
A third-party logistics company with distribution centers in the southeastern United States, a leader in its segment.
4 distribution centers, autonomous mobile robots, industrial sensors, custom ERPRead the case
Zones, conduits and a one-way wire: separating a utility's control network from the corporate network
A regional electric and gas utility with 140 substations and two control centers, a leader in its segment.
140 substations, 2 control centers, ~600,000 meters, 1 Gb/s unidirectional gateway, 4 security zonesRead the case
Robots that stop dropping off the network: private 5G on CBRS spectrum for a Tier-1 auto plant
A Tier-1 automotive supplier in the Midwest, a leader in its segment.
~600,000 sq ft plant, ~18 radio units (replacing ~212 Wi-Fi access points), ~40 AMRs, ~400 machine sensors, ~24 vision camerasRead the case
Private 5G on CBRS for a port terminal: remote cranes, yard tractors and scanners on one radio network
A container terminal operator at a US Gulf Coast port, a leader in its segment.
About 250 acres, 6 berths, 12 outdoor radios, 2 core sites, 3.55 to 3.7 GHz CBRS, 20 MHz carriersRead the caseHow we help
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Learn moreFrequently asked questions
Direct answers to the questions we hear most. Something else on your mind?
Send us a messageHave you worked with factories and industrial plants?
Yes. Our team moved a textile weaving factory from five outdated products to one custom platform, with real-time machine monitoring built on Raspberry Pi sensors for temperature, humidity and vibration. The prototype took two weeks and delivery took three months. We do not name clients.
Can you monitor machines and production in real time?
Yes. We design sensor hardware, industrial enclosures and custom electronics, then collect the readings in software that shows status and alerts on a screen. We measure conditions such as temperature, humidity and vibration so problems show before a machine stops.
How do you secure operational technology networks?
We separate production machines from the office network, limit remote access, inventory every device and plan patching around production windows. Old equipment that cannot be updated is isolated and monitored. We test changes carefully so they do not stop a line.
Can new software connect to our older machines and ERP?
Usually yes. We integrate through sensors, data exports, databases and APIs, even when the equipment is old. We often replace a stack of single-purpose tools with one platform that fits the plant. We assess the equipment first and agree the plan with you.
Do you build custom software instead of buying a subscription?
When a product does not fit your process, custom software can be the better fit, and our team has replaced several products for a manufacturer. We compare the options and their risks with you before you decide. Pricing is discussed during scoping.
What happens to production if the network or a server fails?
We design redundancy for critical parts, such as redundant internet circuits, failover and tested backups. We also write down how to run the plant in a degraded state and how to restore it. The goal is that a failure becomes a short interruption, not a stoppage.
Do you protect against ransomware in industrial settings?
Yes. We use segmentation, patching, endpoint protection, offline and tested backups, access control and monitoring. We also help you plan the response so you know who decides what if production is hit. Penetration tests find weaknesses before an attacker does.