Build Manufacturing Systems Around
Visibility and
Reliability
Cypherox develops manufacturing software, MES platforms and predictive AI systems designed to improve OEE, reduce unplanned downtime, integrate with SAP and deliver the visibility that Industry 4.0 demands.
Security, Data Integrity and
Operational Hardening
Built In
Manufacturing systems control physical production and must be reliable and secure. Cypherox builds around data integrity, machine connectivity, operational resilience and the secure integration of production systems with business applications, so visibility is maintained and downtime is minimized.
Operational architecture from day one
Machine Connectivity and IIoT Security
Secure protocols for machine and sensor data collection, encrypted data transmission and access controls so production data flows into systems without exposing machines to network compromise.
Data Integrity and Production Accuracy
Validate machine data, log production events tamper-proof and ensure traceability so production records are accurate and auditable for quality control.
Operational Resilience and Redundancy
Redundant data pipelines, automated failover and real-time alerts keep product visible even if individual systems fail.
SAP and ERP Integration
Secure APIs connect manufacturing systems to SAP and other ERP platforms, keeping production data, material planning and financial records synchronized.
When Generic Software Fails Manufacturing Operations
Manufacturing environments have requirements that office software cannot meet. Machines generate thousands of data points per minute. Downtime costs thousands of pounds per hour. Production schedules are tight. Data must flow between machines, MES systems and business applications without latency or loss. Cypherox builds systems that address these constraints.
Legacy machines and no centralized view of production data, forcing manual tracking and blind spots in OEE and downtime.
Reactive maintenance triggered by machine failure, causing unplanned downtime and lost production.
Slow root-cause analysis after quality issues, causing batch rework and delays.
Fragmented systems with no connection between production floor data and business planning.
OEE and Production Visibility
Real-time dashboards showing overall equipment effectiveness, downtime, quality issues and production rates so managers see the entire production floor in one view.
Predictive Maintenance
Machine-learning models that predict failures before they occur so you can schedule maintenance proactively and avoid unplanned downtime.
Quality and Traceability
Real-time quality monitoring, root-cause analysis and batch traceability so you catch quality issues early and minimize rework.
Production Planning and MES Integration
Automated production scheduling, real-time capacity tracking and SAP integration so material planning matches production reality.
Specialized Solutions for
Manufacturing
Manufacturing spans production monitoring, maintenance, quality, supply chain and business integration. Cypherox builds across multiple manufacturing domains.
Manufacturing Execution Systems
MES platforms that manage production scheduling, work orders, real-time production tracking and data collection so production teams have visibility and can respond to issues immediately.
Have a Project in Mind? →Predictive Maintenance and Asset Management
Machine learning models that predict failures, condition monitoring systems and maintenance scheduling so you avoid unplanned downtime through proactive maintenance.
Have a Project in Mind? →Quality Management and Traceability
Real-time quality monitoring, statistical process control, root-cause analysis and batch traceability so you catch quality issues early and keep compliance auditable.
Have a Project in Mind? →OEE Analytics and Production Dashboards
Overall Equipment Effectiveness measurement, production analytics and real-time dashboards so you see production performance and can identify improvement opportunities.
Have a Project in Mind? →Digital Twins and Simulation
Digital models of production systems that simulate scenarios, optimize parameters and test process changes before implementing on the production floor.
Have a Project in Mind? →IoT and Machine Integration
Secure data collection from machines, sensors and edge devices, with real-time aggregation and integration into business systems so production data flows seamlessly.
Have a Project in Mind? →Real-World Engineering.
Proven Outcomes.
Predictive Maintenance Reducing Unplanned Downtime
A large UK manufacturing facility ran reactive maintenance, with unplanned downtime averaging 18 hours per month across critical production lines. Cypherox deployed machine-learning models trained on historical machine-sensor data and maintenance records to predict failures 72 hours in advance. Manufacturing teams scheduled preventive maintenance during planned stoppages, eliminating most unplanned downtime. Within twelve months, unplanned downtime fell to 2 hours per month, overall equipment effectiveness improved 22% and maintenance costs declined by 35% by eliminating emergency repair premiums.
Technical Architecture Implemented
- Multi-region active-active Kubernetes clusters on AWS with automated failover under 5s.
- Apache Kafka message backbone processing 14,000+ financial events per second with zero message drop.
- Optimized ONNX AI model scoring incoming wire transfers in 14ms against fraud behavioral vectors.
- PCI-DSS Level 1 certified vault with cryptographic tokenization and automated key rotation.
Built for Production Scale and
Industrial Demands
Manufacturing systems must handle thousands of data points per minute, maintain uptime during critical production windows and integrate with machinery running continuous shifts. Cypherox builds systems designed for production manufacturing engineering.
Ingests tens of thousands of machine data points per second from legacy and modern equipment without data loss or latency.
Maintains 99.95%+ uptime through redundant architecture and automated failover so production visibility never stops.
Handles real-time processing and alerting so operators are notified of issues immediately and can respond before downtime occurs.
Integrates with SAP, MES and legacy business systems so production data flows bidirectionally and accurately.
Request a Manufacturing Technology Review
Share details of your production environment, the machines and systems you need to integrate and your visibility and efficiency goals and we will discuss technical and commercial next steps.
Engagement Models
Tailored to Your Scope
Choose the engagement model that fits your timeline, budget and how much control you want over day-to-day delivery.
Hourly Hiring
Bring in a manufacturing engineer for specific integrations, data collection, or technical investigation without a long-term commitment.
- Pay only for hours worked
- No minimum monthly commitment
- Scale up or down as needed
- Fast to start
Dedicated Monthly
A manufacturing engineer works exclusively on your systems every month, integrated into your team and production cycle.
- Full-time focus on your manufacturing systems
- Consistent engineer across production phases
- Direct communication with your team
- Predictable monthly cost
Fixed Cost Solution
A defined scope, timeline and cost agreed upfront, suited to manufacturing projects with clear requirements and measurable milestones.
- Scope agreed before work begins
- Cost certainty from the outset
- Milestone-based delivery
- Fits well-defined projects
Hire Dedicated Manufacturing Engineers
Work with engineers who understand IIoT, machine integration, production systems and the operational demands of manufacturing platforms.
Hardik
Senior AI and ML Engineer
Available NowBuilds production AI models for anomaly detection, real-time transaction scoring, and predictive risk with automated validation pipelines.
Skills:
Krupa
Senior Full Stack Engineer
Available NowDelivers high-concurrency web and mobile applications with strict security controls, OAuth2 integrations and distributed microservices.
Skills:
Akash
Senior Cloud and DevOps Engineer
Available NowArchitects secure, compliant cloud environments with automated CI/CD, zero-trust infrastructure as code (IaC) and 24/7 telemetry monitoring.
Skills:
Specialized Solutions by
Production
Environment
Manufacturing environments vary in complexity, machine types and production schedules. Cypherox builds across multiple manufacturing contexts.
Discrete Manufacturing and Assembly
Discrete manufacturers need engineers who build production tracking, work-order management and quality systems that handle assembly workflows and component traceability.
- Tracks work orders through multiple production stages.
- Manages component traceability and serialization.
- Monitors assembly quality and rework.
Process Manufacturing and Continuous Production
Process manufacturers need engineers who build real-time process monitoring, parameter optimization and batch management systems that maintain consistency and minimize waste.
- Monitors process parameters in real time.
- Optimizes recipes and process conditions.
- Tracks batch quality and consistency.
Automotive and Tier-1 Supply Chain
Automotive suppliers need engineers who build TISAX-aligned systems, quality tracking and supply-chain integration so they meet OEM requirements and maintain certification.
- Implements TISAX-aligned information security.
- Manages supplier quality requirements.
- Integrates with OEM ordering systems.
Food and Beverage Manufacturing
Food and beverage manufacturers need engineers who build traceability, hygiene monitoring and regulatory compliance systems that ensure safety and enable rapid recall response.
- Tracks ingredients and production batches for recall.
- Monitors hygiene and food-safety parameters.
- Maintains compliance records for audits.
Heavy Equipment and Industrial Production
Heavy equipment manufacturers need engineers who build complex assembly tracking, long-cycle production management and customer-specific configuration systems.
- Manages multi-phase assembly and serialization.
- Tracks customer-specific configurations and options.
- Coordinates supply and production scheduling.
How We Deliver
Manufacturing Software
Manufacturing software requires production discipline, machine understanding and operational integration. Cypherox embeds these into every delivery stage.
The Technology Behind Our
Manufacturing
Solutions
Manufacturing systems connect machines, edge devices, MES platforms and business applications. Cypherox builds across established manufacturing technology.
What Manufacturing
Clients Say
Feedback from manufacturing teams who have worked with Cypherox on real projects, across different engagement models.
Industry Solutions
Questions Answered
These are the questions we hear most often from manufacturing teams evaluating custom software, covering machines, data and integration.
OPC UA, MQTT gateways and edge devices can connect to legacy machines without modifying them. Cypherox implements these connections so you can get data from existing equipment without replacing machines.
Machine-learning models trained on historical sensor data and maintenance records can predict failures 24-72 hours in advance. Cypherox implements these models so you can schedule maintenance proactively.
Yes. Monitoring runs alongside current operations. As the system learns, you gradually increase reliance on predictions so you transition to proactive maintenance without risk.
Data validation, anomaly detection and quality rules catch bad data immediately. Cypherox implements quality checks so dashboards and models only see trustworthy data.
Bidirectional APIs and automated data synchronization connect MES to SAP so production data flows automatically. Cypherox implements these pipelines so manual data entry disappears.
The system scales to new machines and lines by adding connectors and data collection. Cypherox designs modularity so expansion is straightforward.
Let's Discuss Your
Manufacturing Platform
Share details of your production environment, the machines and systems you operate and your visibility and efficiency goals. We will discuss technical and commercial next steps.
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