Industrial Ops

The factory floor generates more data than any system in your business. Almost none of it is used in real time.

We build custom automation and reporting systems that connect your factory floor to your management layer, giving supervisors, plant managers, and leadership the visibility they need to run operations on data, not instinct.

ops-engine / Live Production
Active Work Orders
WO-4187 · PO #29841
Elastomer Housing Assembly
84 / 100 units
QC: PendingIn Production
WO-4192 · PO #29856
Avionics Bay Seal
50 / 50 units
QC: ✓ PassedReady to Pack
Sync Latency
1.4s
ERP to floor
First Pass Yield
97.2%
↑ Real-time
Orphan Entries
0
Since go-live
QC GATE
WO-4187 packing blocked until QC verification complete. 16 units awaiting inspection.

Knowing what's happening on your floor shouldn't require waiting until end of shift.

For decades, real-time production monitoring and floor-to-management reporting were only accessible to large manufacturers who could afford dedicated industrial software platforms, platforms that came with seven-figure license fees, multi-year implementations, and consultants who charged by the hour to configure something that still didn't quite fit.

Mid-size manufacturers ran on spreadsheets, whiteboards, and paper shift reports filled in from memory. Modern development tools and AI have changed that equation entirely, making purpose-built systems accessible without a seven-figure software license.

Connecting the factory floor to the people who need to act on it.

Real-Time Line Monitoring

Know what's happening on every line as it happens: output rates, downtime, stoppages, and performance against target. Supervisors see it live. Managers see it rolled up. Leadership sees the trend. No more waiting for someone to compile a report.

Production Output & Performance Reporting

You should know by lunchtime whether your lines are on track to hit today's target, not at end of shift when it's too late to do anything about it. We build reporting that tells you what's happening now, not what happened.

Shift & Attendance Tracking

Automated shift logging and attendance records, connected to your payroll and HR systems. Supervisors spend less time on paperwork and more time on the floor managing their teams.

Floor Supervisor Dashboards

Purpose-built dashboards for supervisors, showing what they need to act on right now. Not a generic report built for the boardroom. A tool built for someone standing on a factory floor with thirty seconds to make a decision.

Quality & Compliance Reporting

Defect tracking and compliance documentation captured digitally at the point of production, not reconstructed from memory at the end of the week. Full audit trail, always current.

Management Reporting & BI

Everything that happens on the floor, aggregated, visualised, and delivered to plant managers and leadership. Daily summaries, weekly trends, cross-site comparisons, automated and accurate.

The missing link between your systems and your factory floor.

Most manufacturers have two worlds that barely talk to each other. Your business system holds the production orders, inventory, and master data. The factory floor is where work actually happens. Between them sit spreadsheets, phone calls, and manual data entry that introduces delay and error at every step.

We build the connectivity layer in between, capturing data from the floor in real time, connecting it to your business systems, surfacing it to the right people. No rip-and-replace. No seven-figure platform. Built on modern tools, connected to what you already have.

Power BI Azure Python SQL REST APIs ERP Integration OpenAI / Gemini / Claude Custom Web & Mobile Apps

The Process

01

Understand the Floor

We spend time on site, talking to supervisors, operators, and plant managers. We map the data that exists, the data that's missing, and the decisions people are trying to make with it. We don't design from a conference room.

02

Design the System

We design the data model, the connectivity architecture, and the reporting layer. You review it before we build anything.

03

Build & Integrate

We build on your existing infrastructure, connecting to your business systems and management layer. Custom-built for your operation, not adapted from a generic template.

04

Deploy & Train

We roll out to supervisors and managers with hands-on training. Built to be used by people on a factory floor, so it's simple, fast, and reliable.

05

Maintain & Evolve

As your operations change, with new lines, new products, and new reporting requirements, we keep the system current. Or we hand it over fully documented so your team can maintain it independently.

Who this is for

Plant Manager / Operations Director

You need to know what's happening on every line without waiting for someone to compile a report. You need to know about a problem when it happens, not an hour later when it's already cost you output.

COO / VP Operations

You're making capacity and scheduling decisions on data that's hours or days old. You need a management layer that reflects reality, across sites, in real time, in a format you can act on.

Shop Floor Supervisors

You shouldn't be spending half your shift on manual paperwork and data entry. You should be on the floor managing your team, with a dashboard that tells you exactly where to focus.

Finance

Production data that connects to your financial systems automatically. Output volumes, shift costs, and quality losses that roll up to the numbers you need for period-end reporting, without a manual reconciliation exercise.

Manufacturing & Industrial, across discrete manufacturing, process industries, and mixed-mode operations

What Falcon Incentives builds at scale.

Case Study

Real-Time Production Control

How we delivered real-time production floor visibility, connecting line-level output data to shift supervisors and plant managers through live dashboards and automated alerts.

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Heard from the field

"
Falcon Incentives has been excellent to work with. Tarun built a powerful app for us and although we are still exploring all of its capabilities, it was intuitive from day one with minimal instructions, which is exactly how an app should work. We use it to track our production line and monitor progress on every part. Tarun is extremely responsive and a pleasure to work with!
PJ
Pam Johnson
Ultimate Solutions
Industrial Ops Automation Custom App

Tell us what your floor can't see today.

We'll tell you what it takes to close the gap, and whether a custom-built solution makes sense for your operation.