Industries · Manufacturing
Stop finding out from the customer. Run the plant.
Plutonic builds manufacturing software and AI for Indian plants — quality, maintenance, inventory, and shop-floor status tied to the ERP you already run.
- Your QC manager still hears about a defect from the buyer, not from the line
- Stores, WIP, and FG never match — so you overbuy or miss the truck
- Breakdowns are a surprise because sensors and work orders don't talk
- Monday MIS is Excel that someone built at 11pm on Sunday
Overview
What a plant actually needs from software
Challenges
If this is your week, keep reading
The customer is your QC alarm
Defects leave the plant after value is already added.
- Rework after packing — labour and material already spent
- No photo or reason code the next shift can use
- Holds live in WhatsApp, not against the batch
Three inventory numbers. None trusted.
Stores, WIP, and finished goods disagree across plants.
- Planners pad the indent because they don't trust the screen
- One plant ships while another sits on the same SKU
- Adjustments happen in Excel, then someone 'updates SAP later'
Maintenance is still break-fix
Machines fail without a work order the store can pick against.
- Telemetry exists. Nobody owns the alert
- Spares are guessed, not reserved
- The line waits while the fitter hunts a part
The line moved. The report didn't.
Leadership decides on last night's spreadsheet.
- OEE is a monthly argument, not a live number
- Holds and shortages show up in the meeting, not on a phone
- Shift handover is a notebook
Solutions
What we put on the floor
Solution 01
Catch it before packing
The mess
Defects show up after the value is already in the box.
What we put in
Inspection assist and hold ownership on the batch — with a human override on the calls that matter.
- Vision or checklist QC at the station, not after FG
- Hold reason, photo, and owner on the lot
- NCR that a supplier can actually answer
Solution 02
One stock figure the planner will use
The mess
Stores, WIP, and FG never agree, so everyone pads the indent.
What we put in
Movements and adjustments in one picture across plants — tied to the ERP, not a side spreadsheet.
- Receipt, issue, and transfer that match the floor
- Multi-plant view a planner can defend in the meeting
- No 'we'll update SAP later'
Solution 03
Stop the surprise breakdown
The mess
The machine dies and then someone raises a ticket.
What we put in
Signals, work orders, and spares in one queue so downtime is scheduled.
- Alert that becomes a job, not a WhatsApp ping
- Spare reserved against the job
- Fitter sees the queue on a phone, not a printout
Solution 04
Numbers while the shift is still on
The mess
You find out at 9am what broke at 2am.
What we put in
OEE, holds, and shortages to the role that can act — in minutes.
- Supervisor phone, not a war-room TV only
- Exception list, not 40 charts
- Handover that the next shift can open
Capabilities
What we actually build for plants
01
Vision QC & inspection
Catch defects at the station, with a person still in charge of the hold.
- Station-level review
- Photo + reason on the lot
- Human override on critical SKUs
02
Maintenance that is a queue
Sensors, jobs, and spares connected so the fitter is not hunting.
- Alert → job
- Spare reserved
- Phone queue on the floor
03
Planning that respects the ERP
Forecast and capacity aids that sit on your orders, not a toy model.
- Tied to ERP demand
- Capacity you can argue with
- No second planning universe
04
MES / shop-floor status
Orders, BOM, routing, and 'where is this batch' without another whiteboard.
- Live order status
- Routing the line actually runs
- Works with gloves and noise
05
Warehouse that matches the floor
Movements ops will trust on Monday morning.
- Multi-location stock
- Adjustments with a name on them
- No parallel Excel store
06
Plant dashboards people open
Exceptions, not a 20-tab MIS.
- OEE and holds
- Shortage risk
- Role-based, not one TV for everyone
07
Supplier & NCR portals
Certificates and non-conformance that don't live in email.
- Structured NCR
- Supplier reply in the record
- Certificate intake
08
Integrations that don't expose the plant
PLC, historian, ERP, cloud — without opening the factory network carelessly.
- ERP you already pay for
- Shop-floor data with a fence
- No rip-and-replace as day one
Use cases
Jobs a plant owner will pay for
Cut scrap on one line first
Pilot QC on the line that hurts most. Expand when the number moves.
- One line, one defect type
- Hold ownership from day one
- Roll out after the scrap graph bends
Make downtime a calendar item
Condition-based jobs instead of 2am panic.
- Alert with a spare
- Scheduled window
- Less 'the line is down, come now'
Stop padding the indent
Give planning one stock number they will actually use.
- Stores + WIP + FG
- Plant-to-plant visibility
- Fewer emergency purchases
Kill the Sunday MIS
Exceptions to the phone, not a 40-tab workbook.
- Live holds and shortages
- Shift handover in the system
- Meeting starts with facts
Recommended services
Where to start in our practice
Why it matters
Why plants stay with us
We talk WIP, not 'digital transformation'
If we can't name the hold and the station, we don't belong in the kickoff.
- Throughput and OTIF
- Scrap and downtime
- No buzzword kickoff
We plug into the ERP you have
AI that lives beside SAP is a toy. We wire it in.
- No rip-and-replace as the pitch
- Shop floor + ERP
- Pilot on one line
Screens a fitter will use
Gloves, noise, shift change — not only an office laptop.
- Big targets
- Phone-first where it matters
- Handover that survives the shift
You can point at a number
Scrap, downtime, OTIF, inventory accuracy — not 'AI adoption'.
- Baseline before we start
- One owner per metric
- Expand when it pays
FAQ
Manufacturing questions
Yes. Most plants keep SAP, Tally, or whatever they already pay for. We wire into it. Rip-and-replace is not the opening move.
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