Industry solutions · Manufacturing & Automotive
When material flows, MES, machines and production planning don't work together seamlessly, delays, manual tasks and blind spots emerge on the shop floor.
VIALUTIONS develops and integrates custom software for manufacturing—from digital shop floor workflows and MES modernization to the long-term support of business-critical applications.
Engineering from Berlin & Wrocław · English-speaking collaboration · Experience in industrial environments
What matters in manufacturing
The challenge
In complex manufacturing environments, many things work—often thanks to Excel, paper, manual handovers and the knowledge of individual employees. As throughput requirements, product variants and integration demands increase, these workarounds become bottlenecks.
Production updates are recorded on paper, in spreadsheets or in isolated applications.
Machines, production control and business systems generate data, but not a shared view of the process.
Long-established solutions are critical to operations but difficult to modify or replace.
Downtime, scrap, material requirements and process deviations become visible too late or require too much effort to identify.
How we help
We work where off-the-shelf products reach their limits: process logic, interfaces, data flows and the ongoing development of existing applications.
Take over existing MES environments, extend functionality, gradually replace legacy components and meet specific operational requirements.
Integrate machine and process data, visualize production status, and systematically capture downtime and deviations.
Digitally support parts demand, locations and delivery—getting the right parts to the right production point at the right time.
Keep historical production and quality data from outdated applications accessible and usable over the long term.
Replace paper-based processes and disconnected Excel files with tailored applications and clear responsibilities.
Build interfaces to existing enterprise systems, deploy changes safely and continuously improve critical applications.
Machine Monitoring · Condition-based manufacturing
Many machines already generate data—but it often remains in controllers and loggers, while production planning has no visibility into the actual equipment condition. VIALUTIONS connects industrial measurement technology, data analysis and existing MES processes, turning raw measurements into actionable information for maintenance and planning.
Detect deviations early. Plan maintenance based on machine condition. Help prevent unplanned downtime.
Vibration, temperature, strain, current, voltage and digital machine states.
Digitize, preprocess and buffer measurements locally at the machine.
Derive machine-specific KPIs, trends, anomalies and maintenance needs.
Bring machine conditions and events into maintenance scheduling and capacity planning.
Integration tailored to your system landscape
Business value
✓ Higher equipment availability through earlier indications of wear and deviations.
✓ More targeted maintenance instead of rigid intervals and avoidable emergency repairs.
✓ More realistic production planning based on actual machine availability.
1. Analyze the machine and typical failure modes → 2. Install sensors and evaluate data → 3. Deliver results to the MES or through an interface. Then scale to more machines and sites as needed.
Projects in practice
Six examples show different starting points—from parts supply to ongoing MES development.
Automotive · Toyota
An In House Part Logistics solution was developed to determine parts requirements, track part locations and provide information on strategically positioned tablets.
Objective: less waiting and unnecessary trips, with improved parts availability at the point of production.
Manufacturing · MES
An existing MES was adapted and maintained to support versioned production recipes, connected machines and site-specific requirements.
More than 10 years of adaptation and maintenance across European plants.
Automotive · Toyota
The vKaizen solution digitalized continuous improvement by systematically capturing and processing employee suggestions.
Within 1.5 years: average processing time fell from six weeks to one; 18% more suggestions were submitted.
Automotive · Brake manufacturing
Data was extracted from an Oracle-based application that could no longer be upgraded and made available for long-term use in a new application.
Context: legal requirements to retain parts data for more than 10 years.
Manufacturing · MES
Components of a solution based on Siemens SIMATIC Production Suite were progressively replaced with custom developments, including bidirectional machine integration.
Control of more than 100 pieces of equipment, including integrated SCADA functionality.
Manufacturing · Production dashboards
Production dashboards visualize machine parameters, output, scrap, orders, downtime reasons and inspection data.
Objective: second-by-second process visibility and faster responses to deviations.
Our approach
We start by understanding critical workflows and dependencies. From there, we define a realistic path forward—with interfaces, documented business logic and controlled rollout stages.
01 · UnderstandAssess processes, the system landscape and bottlenecks together
02 · PrioritizeEvaluate business value, risk and integration effort
03 · ImplementDevelop, integrate, test and deploy step by step
04 · EvolveMaintain long-term operability, transparency and reliability
A good starting point
Let's talk about your bottleneck
Whether it's MES, materials flow, production data, machine monitoring or legacy systems: briefly describe your situation. We'll discuss what can be improved technically and with manageable risk.
✓ Which process or system is affected?
✓ Which existing interfaces need to remain in place?
✓ What is the right first step—assessment, prototype, system takeover or integration?
Contact · Manufacturing & Automotive
Send us your inquiry directly using the form.
