Manufacturing software development for the factory floor
We build ERP, shop-floor, quality and machine-monitoring software around how your plant actually runs, so planners, supervisors and owners work from the same live data.
We provide manufacturing software development for discrete and process manufacturers, contract manufacturers, food and packaging plants, and engineering workshops. ZedBlu builds the systems that connect a sales order to purchasing, the shop floor, quality control and dispatch, so everyone works from the same numbers.
Many factories run on a mix of an accounting package, a dozen spreadsheets and a whiteboard beside the production line. Off-the-shelf ERPs promise to replace all of that, yet they often force plants to change proven processes or pay for heavy customization. We take the opposite approach: map how work actually flows on your floor, then build or extend software to match it.
Rollouts happen in phases, often one line or department at a time, with training for operators and supervisors. Your team sees progress in weekly demos, owns the source code and gets maintenance support once the system is part of daily production.
What slows teams down
No live view of production
Work in progress is tracked on paper job cards and whiteboards, so managers learn about delays at the end of the shift. Without shop floor management software showing live status by order, machine and operator, delivery promises become guesswork.
Material shortages and excess stock
Planning purchases on spreadsheets stops lines when a component runs out, while other materials sit in the store for months. Bills of materials, lead times and reorder levels rarely live in one reliable system.
Quality issues found too late
Inspection results recorded on paper make it hard to trace a defect back to a batch, machine, shift or supplier. Problems then surface at the customer's site, where they cost the most to fix.
Machines that produce no data
Older machines and PLCs run without connectivity, so downtime causes, cycle times and maintenance needs go unmeasured. Breakdowns arrive without warning and maintenance stays reactive instead of planned.
Software that fits how you work
Custom ERP for manufacturing
Sales orders, bills of materials, production planning software, purchasing, batch-wise inventory by location, job work, costing, dispatch, shift attendance and GST or VAT invoicing in one system designed around your products and processes.
Shop-floor and MES apps
MES software development for tablets and phones: operators start and close jobs, record output and scrap, log downtime reasons and view work instructions, while supervisors watch a live board of every line and order.
Quality management and traceability
Quality management software with digital inspection checklists, sampling plans, photo evidence, non-conformance reports and corrective actions, plus batch and lot genealogy that traces any finished item back to its raw materials.
IoT machine monitoring
IoT solutions for manufacturing that read PLC and sensor signals for run time, cycle counts, temperature and vibration, feeding OEE dashboards and predictive maintenance software that flags early signs of wear.
Computer vision inspection
Camera systems trained to spot visual defects, verify labels and count items on the line, flagging rejects as they happen and building an image record of quality over time.
Dealer, supplier and service portals
Web portals where distributors place orders and track dispatch, suppliers confirm purchase orders and upload invoices that AI reads automatically, and after-sales teams log installation and service visits through a field service app.
Ready-made solutions for Manufacturing
Services we bring
Manufacturing: FAQ
How much does manufacturing software development cost?
It depends on the modules, number of plants and integrations. A focused shop-floor app or quality module typically costs $8,000 to $25,000, while a custom manufacturing ERP covering planning, inventory and costing usually costs more and can reach enterprise budgets for multi-plant operations. Machine connectivity and IoT hardware are quoted separately, and a fixed quote for the software follows a free consultation.
Can you connect our machines and PLCs to the software?
For most equipment, yes. Modern machines often support OPC UA, Modbus or MQTT, and older ones can be connected through IoT gateways, current sensors or I/O modules. We review your machines, controllers and network first, then propose the least disruptive way to collect run time, counts and alarms. Data then reaches dashboards and alerts without operators typing numbers by hand.
Should we customize an off-the-shelf ERP or build our own?
If your processes are standard and an ERP already fits most of them, customizing it is usually cheaper. A custom build makes sense when your workflows are unusual, when license costs keep rising with headcount, or when the ERP has been bent so far that upgrades break things. Our manufacturing ERP solution offers a middle path: a ready base that we adapt to your processes.
Will the new software work with our existing accounting and ERP systems?
Yes. We integrate through APIs, database connectors or scheduled file exchanges, depending on what your current systems support. A common pattern keeps accounting where it is while the new software handles production, quality and inventory, with invoices and stock values synchronized automatically. That avoids a risky all-at-once migration and protects your finance team's existing workflows.
How do you roll out new software without disrupting production?
We start with a pilot on one line, department or product family, run it alongside existing records and fix issues before expanding. Operators get short, hands-on training on the devices they will actually use, and screens are designed for gloves, noise and limited time. Go-live dates are planned around your production calendar, with close support during the first weeks of live use.
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