Manufacturing runs on data that rarely sits in one place. Production plans live in the ERP, machine signals in the MES or PLC layer, quality records in spreadsheets, and supplier documents in email. Custom software and AI components can connect these sources, so planners, quality engineers and plant managers work from one accurate picture instead of reconciling four.
What this kind of automation can achieve
The challenges
The ERP holds orders and material data, the shop floor holds reality. Without integration, production feedback arrives late or by hand, so plans drift from what machines are actually able to run this shift.
Inspection results, measurement protocols and non-conformance reports are still typed into spreadsheets and re-typed into the quality system. Traceability suffers, audits become archaeology, and defect patterns stay invisible until a customer complains.
Machine stoppages get logged with vague reason codes or not at all. Nobody can tell whether a line lost hours to changeovers, material shortages or a recurring fault, so improvement work is based on opinion rather than evidence.
Order confirmations, delivery notes, certificates of analysis and material declarations arrive as PDFs in shared mailboxes. Purchasing staff open each one, copy values into the ERP and chase discrepancies manually across dozens of suppliers.
What can be built
Reliable two-way interfaces between production systems, ERP such as SAP or Microsoft Dynamics, and machine data sources, with queuing and error handling so nothing is silently lost between systems.
Custom planning and scheduling applications that reflect your real constraints: tooling, changeover times, shift patterns, material availability and priority orders, instead of forcing your process into generic software.
Automated extraction from order confirmations, delivery notes, certificates and invoices, with validation against purchase orders and structured handover into the ERP, so people only review the exceptions.
Collection of machine signals and operator input into a single view of availability, performance and quality, with clear reason codes, shift comparisons and drill-down to individual lines and workstations.
An internal assistant that answers questions from work instructions, maintenance manuals, safety documentation and past fault reports, so technicians find the right procedure without searching shared drives.
Savings potential
These are model estimates of what this kind of automation can do — not measured results from our own projects. We recalculate them on your real volumes and systems before anyone commits to anything.
Contact
Tell us about your project, the bottleneck in your processes, or the legacy system you've outgrown. We're available 24/7 and we reply to messages promptly — with concrete next steps, no obligation and no sales theater.
info@durfinasystems.com +421 918 513 248
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