Industry 4.0, without the jargon.

Because most plants cannot answer basic questions quickly: which machine lost us the most output last week, why a batch failed, which tool is due for change, whether today's schedule is achievable. Without instrumentation those answers arrive weeks late, if at all.

Connected systems close that gap. They make losses visible while they are still happening, which is the only point at which someone can do something about them.

IoT is the general idea of connected devices. IIoT is the industrial subset — machines, controllers and sensors in production environments, where reliability, determinism and safety matter far more than in consumer applications.

Industry 4.0 is the broader operating model: IIoT connectivity plus MES, digital quality, traceability, simulation, robotics and the organisational changes needed to use them. IIoT is a component; Industry 4.0 is the programme.

That is a design decision, not a leap of faith. The MAPP platform runs either fully on-premise inside your plant network — where no production data leaves the site — or in a hosted environment with region-selectable residency, depending on your IT policy.

Either way the platform uses role-based access control, audit trails and version control, and our vision products can perform inference entirely on local infrastructure. We scope security requirements with your IT team before deployment, not after.

Typically: real-time visibility of machine, line and plant performance; reduced downtime through live alerts and reason-coded stoppages; higher productivity from bottleneck analysis that shows where improvement effort actually pays; better quality through digital inspection and SPC; and faster, more defensible traceability when a customer or auditor asks.

The specific numbers depend on your starting point. We benchmark before we quote so the business case is yours, not a brochure average.

It scales with the number of machines connected, the modules deployed and whether existing equipment needs retrofitting to expose data. A single-line MAPP EYE deployment is a very different commitment from a multi-site MES rollout with quality, maintenance and scheduling.

Because MAPP is modular, most customers start with one module on one line, prove the return, and expand from there. We will always tell you which phase we would do first if it were our money.

Start with a scoped assessment: what equipment you have, what data it can already expose, where your biggest losses are, and what you need to report to whom. That usually takes a short site visit and a conversation with production and IT together.

From there we recommend a first phase small enough to deliver quickly and significant enough to prove value — commonly performance monitoring on a single constrained line.

Yes. Database and ERP integration is a core part of the platform. MAPP ADEPT synchronises production orders from ERP and writes WIP updates back; MAPP TRAIL maps supplier-to-customer material genealogy; and reporting modules can push consolidated data to BI tools.

Integration is scoped per customer, since every ERP deployment differs in structure and available interfaces.

Because the whole scope sits with one team. Electrical design, controls software, robotics, virtual commissioning, MES platform and onsite commissioning are all delivered in-house — so responsibility never falls between two suppliers when something does not work.

We have been doing this since 2003, across 400+ projects in 30+ countries, under an ISO 9001:2015 quality system, and we are deliberately brand-agnostic across Siemens, Rockwell, Beckhoff, Mitsubishi, Delta, KUKA, FANUC, ABB and Yaskawa.

Yes — from feasibility and cycle-time study through electrical design, panel build, software development, virtual commissioning, onsite commissioning and operator training.

After handover we provide ongoing maintenance, troubleshooting, software updates and system enhancements, under annual maintenance contracts that include 24/7 remote support.

Engineering is delivered from our offices in Warje, Pune and Valasarvakkam, Chennai. Commissioning teams travel to customer factories worldwide — we have delivered projects in more than 30 countries.

Routinely. A large part of our work is diagnosing performance problems in legacy or third-party systems and proposing modern upgrades — including SCADA integration, retrofitting, re-tooling and full line relocation.

Where documentation is missing we reverse-engineer the existing control scheme as part of the assessment.

Virtual commissioning tests the real control code against a simulated model of the machine before anything is installed. Collisions, sequence errors and logic faults get found in software rather than during a production window.

It is most valuable when onsite time is expensive or scarce — overseas installations, tight shutdown windows, or complex multi-robot cells. On such projects the onsite phase is materially shorter, because the sequence has already been proven against a model of the real cell.