Software for the plant and everything around it
Manufacturing businesses run on two kinds of systems. Operational technology controls machines and processes on the floor. Enterprise systems handle planning, purchasing, inventory, finance and sales. The value of digital work in manufacturing usually sits in the gap between the two: getting reliable, timely data from machines and people on the floor into the decisions made everywhere else.
Twara Technologies designs, engineers and supports that connecting layer, along with the portals and apps that extend a manufacturer’s reach to dealers, distributors and field service teams. We build for discrete and process manufacturers, from single plants to multi-site operations, and we build around the equipment and systems already in place.
What we build
IoT solutions
Edge gateways that collect data from PLCs, CNC controllers, energy meters and retrofitted sensors using standard industrial protocols such as OPC UA and Modbus. Local buffering so data survives network outages. Secure device provisioning, remote configuration and controlled firmware updates.
Web development
Production, OEE and energy dashboards; quality and traceability systems; maintenance management; dealer and distributor portals; supplier portals for purchase orders, delivery schedules and invoices.
Mobile app development
Operator apps for checklists, downtime reasons and output entry. Maintenance apps for work orders, spares and readings. Field service apps for installation, commissioning and warranty visits, with offline support.
Cloud services
Industrial data platforms with time-series storage, data pipelines and reporting, deployed on major cloud providers or in a hybrid arrangement where some processing stays on-site.
AI and machine learning
Predictive maintenance, visual inspection, demand and production forecasting, and energy optimisation. Every model is piloted on a defined scope with agreed success measures before wider roll-out.
Support and maintenance
Monitoring, patching and incident handling for gateways, integrations and applications, with change control that respects production schedules.
Compliance, standards and data considerations
This section is general information, not legal or certification advice.
Industrial cyber security. The ISA/IEC 62443 series sets out requirements and processes for securing industrial automation and control systems across their lifecycle. It assigns responsibilities to asset owners, product suppliers, integrators and service providers. We use it as a reference when designing network segmentation, remote access and device security for connected plants.
Product certification. The Bureau of Indian Standards explains that its certification is broadly voluntary, but the Central Government makes the Standard Mark mandatory for specified products through Quality Control Orders, under a BIS licence or certificate of conformity. Where your products fall under such an order, your quality and traceability systems should record the relevant licence, standard and test data alongside each batch. We build the software; certification itself stays with you and BIS.
Incident reporting and logs. CERT-In’s directions of 28 April 2022 require service providers, intermediaries, data centres, body corporates and government organisations to report specified cyber incidents within 6 hours of noticing them, and to keep logs of their ICT systems for a rolling 180 days within Indian jurisdiction. Logging and alerting in plant systems should be designed with this in mind.
Personal data. Employee, dealer and customer data in portals and apps falls under the Digital Personal Data Protection Act, 2023 and the DPDP Rules, 2025, including the rule 6 security safeguards.
Integrations commonly needed
- PLCs, CNC controllers, SCADA and historians, via OPC UA, Modbus or MQTT
- ERP systems for production orders, bills of materials, inventory and costing
- Manufacturing execution and quality management systems, where present
- Computerised maintenance management systems
- Energy meters and utility monitoring
- Dealer management, CRM and e-invoicing or e-way bill generation through the ERP
- Identity providers for single sign-on across plant and office users
How an engagement typically starts
Manufacturing engagements usually start on the floor. We walk the plant with your production, maintenance and IT teams, list the machines and their controllers, review network layout and security constraints, and agree the decisions you most want better data for. The output is an equipment and integration survey, a target architecture and a pilot scope: typically one line or a group of critical assets, with success measures defined in advance.
A pilot proves connectivity, data quality and usefulness before investment scales to more lines or sites.
Principles we design by
- Production comes first. Data collection must never interfere with machine control. Gateways read data; they do not write to controllers unless that is explicitly designed, reviewed and tested.
- Work offline, sync later. Plant networks fail. Edge devices and shop-floor apps keep working and catch up when connectivity returns.
- Agree definitions before dashboards. Downtime reasons, OEE formulas and shift boundaries are agreed with your teams so every report means the same thing on every line.
- Security by segmentation. Plant and enterprise networks stay separated, remote access is controlled and logged, and devices are updated through a managed process.
- Built to hand over. Documentation, runbooks and training let your engineers own and extend the system.
To discuss your plant, contact us.