Data Infrastructure Engineering for Manufacturing & Industrial
Sensor data from the plant floor and the system that runs the business usually live in two different worlds. We connect production telemetry to the systems finance and planning depend on, and modernize the legacy Oracle or SQL Server underneath without stopping the line.
Where Manufacturing Data Infrastructure Actually Breaks
Plant-floor telemetry lands in a historian built for time-series sensor data. The ERP runs on a relational database built for transactions and reporting. Neither is wrong for its job, but neither was built to answer the other's questions, so production and finance end up stitching two exports together by hand to answer something that should be a single query.
The ERP itself accumulates its own drag over time. A report that took 20 minutes when the line was smaller takes three hours a few years later, and everyone just plans their day around waiting for it, because nobody's had time to profile the query underneath it.
Sensor data adds a quieter risk. A firmware update changes a device's output format, and nothing throws an error, a downstream production or quality report just quietly stops reconciling until someone notices the numbers look wrong.
We scope plant-floor integration, database performance, and legacy modernization to the specific systems causing the gap, without stopping the line to do it.
Five Problems We See Repeatedly, and How We Handle Them
Real scenarios, not a checklist of generic capabilities.
Plant-floor telemetry lands in a historian built for time-series data, and the ERP runs on a relational database built for transactions, so production and finance can't answer the same question without someone stitching two exports together by hand.
We build the streaming integration layer between them, so operations and finance query current data without a manual export.
Real-Time Data EngineeringAn ERP report that took 20 minutes years ago now takes three hours, and everyone just plans their day around waiting for it.
We profile the actual query and indexing and fix the specific bottleneck, the same way we cut one manufacturer's Oracle Reports runtime from three hours to 15 minutes with zero downtime.
Database EngineeringA sensor firmware update silently changes its output format, and nobody notices until a downstream production report doesn't reconcile.
We build schema contract enforcement that catches a format change before it corrupts downstream data, not after.
Data ReliabilityThe Oracle or SQL Server ERP underneath production has run for a decade, and a license renewal or performance ceiling makes migrating look necessary, but stopping the line isn't an option.
We migrate with dual-write or CDC-based replication so the line keeps running, with a rollback path at every cutover phase.
Data ModernizationProduction planning and procurement still run on last year's demand numbers, so a line gets scheduled against a forecast nobody's updated.
We build demand forecasting and production-planning optimization off your actual order and inventory data, so scheduling and procurement work from a current signal, not a stale plan.
Data AnalyticsFrom Recent Engagements
Cut Oracle Reports generation from 3 hours to 15 minutes and eliminated Oracle Forms timeouts for a manufacturing ERP, with zero production downtime.
Read the case studyTechnology We Work In
PostgreSQL and MySQL as migration targets, Kafka for plant-floor and IoT streaming, InfluxDB for time-series sensor data, and Grafana for dashboards and alerting.
We work hands-on with: PostgreSQL, MySQL, Kafka, InfluxDB, Grafana.
What's Included, By Category
Plant-Floor & Real-Time Integration
- Streaming ingestion from historians and IoT/sensor sources on Kafka
- Schema contract enforcement that catches firmware or format drift before it corrupts data
- Operations-to-finance and planning system integration
- Database performance tuning for MES and quality-tracking systems under continuous load
Legacy ERP Modernization & Migration
- Oracle or SQL Server ERP database migration with zero-downtime cutover
- Dual-write and CDC-based replication with a rollback path at every phase
- Stored procedure translation for vendor-specific logic
- Phased modernization sequenced around production schedules
Database & Reporting Performance
- Query optimization for ERP reports, reconciliation, and production reporting
- Connection pooling and resource tuning under continuous production load
- Replication, failover, and backup/recovery for production-critical systems
- Cloud database cost optimization for legacy systems moving to managed infrastructure
Market Segments Served
We work with manufacturers where plant-floor integration, ERP performance, or legacy migration risk is the actual problem.
- Manufacturers whose plant-floor and ERP systems can't answer the same question
- Companies whose ERP reports or reconciliation jobs have gotten slower as production scaled
- Manufacturers running a legacy Oracle or SQL Server ERP they can't take offline to modernize
- Operations teams whose sensor or IoT data pipeline broke silently from a firmware change
- Manufacturers consolidating plant-floor, MES, and ERP reporting into one accessible system
- Industrial companies ahead of a license renewal or performance ceiling on a decade-old database
Delivery Lifecycle
Discovery & Assessment
We map dependencies across your plant-floor, ERP, and reporting systems, and assess migration risk on your legacy database.
Architecture & Design
We design the streaming ingestion and modernization sequence, with an explicit cutover and rollback plan for each phase.
Build & Integration
We implement the integration pipelines and migration work end to end, sequenced around your production schedule.
Testing & Validation
We validate against real production data and load, with a tested rollback at every phase, without stopping the line.
Launch & Ongoing Coverage
We document runbooks, train your team, and stay on retainer for schema drift, incidents, and the next modernization phase.
Why Manufacturing Teams Work With Us
Depth Across the Whole Stack, Not Just One Layer
An integration vendor connects the historian to the ERP. A DBA tunes one database. We bring integration, migration, and database performance engineering as one team, so a problem that crosses two systems doesn't fall into the gap between vendors.
A Team, Not One Person's Calendar
A single in-house hire means business hours and one person's availability, with everything waiting when they're out. We bring a team behind every engagement, so a production reporting issue doesn't wait on someone's vacation.
Every Migration Ships With a Rollback Path
Dual-write or CDC-based replication keeps the old and new systems in sync during the transition, so a cutover on a system the line depends on isn't a bet, it's a reversible step.
No Dependency by Design
Runbooks and documentation are part of the deliverable, so your team can run what we build without staying on retainer forever. If ongoing coverage is still the right call, we'll say why.
Related Services
Frequently Asked Questions
Find Out Where Your Plant-Floor Data Actually Breaks
We schedule a call to hear what's going on, then a second call to review your systems and tell you directly which gaps carry real risk.