Factory Operations Platform
A complete factory floor management system — operations, communications, quality, dispatch, and scheduling — running on standard server hardware with zero software license fees. Every feature you see here is working. Every planned feature has a detailed architecture and implementation roadmap. Explore the system.
I walked into my first factory in 1985. Over the decades since, I've worked in and around manufacturing operations and seen the same problems repeat across every plant I've been in — poor communication between stations and shifts, information trapped in people's heads instead of systems, equipment failures that could have been predicted, and manual processes that waste time and money every single day.
I've been writing code since the 1980s, across more languages than I can count, and I've been coding to databases since the early '90s. I was doing networking back when it was done with coaxial cables. During my time away from the factory floor taking care of family matters, I kept building — and when I came back, I brought 40 years of factory experience together with decades of software development, database design, real-time communications, and AI (Artificial Intelligence)-driven analysis. This system is the result.
This isn't theoretical. Every feature here was designed because I've seen the problem it solves — on the floor, with my own eyes, across multiple factories and decades of operations. The planned features are built on the same foundation: real problems that cost real money, with real solutions that are ready to build.
Factory Floor Operations
Every furnace, deck, autopour, and inoculation station runs from configurable control panels. Recipes, batches, heats, pours, schedules, and work instructions — all managed from any browser on any device. Panels are built from 19 widget types that management can configure without code changes.
Factory-Wide Communications
Station-to-station text messaging, voice message recording, browser-based VOIP (Voice Over IP) calling with intercom and all-call, file and document sharing, and distribution groups. Every station has a mailbox. Messages deliver instantly. Replaces radios, paper notes, and whiteboard messages entirely.
Forklift Dispatch & Safety
Departments request forklifts with one tap. Drivers claim and complete tasks in real time. Status flows back to the requesting station instantly. Planned: dual-monitor workstations with rear/side cameras, obstacle detection, and health monitoring that catches equipment failures before they happen.
Quality & Problem Tracking
One-tap problem reporting from any station with common problem libraries per area. Active problems are visible factory-wide the moment they're reported. QC (Quality Control) testing requests flow between departments with real-time status tracking. Full resolution workflow with history.
Scheduling & Production Data
Full annual plant calendar with monthly tabs, holidays, shutdowns, and department events. Crew scheduling with certification enforcement and coverage gap detection. Batch lifecycle management, heat logging with path tracking, pour weight recording with actual vs target comparison. Full production history from any station.
Employee Self-Service Portal
A separate lightweight app on a $5-10/month VPS (Virtual Private Server) that employees access from their phone. Personal calendar with scheduled shifts, approved vacation, and plant holidays. Submit PTO (Paid Time Off) requests, claim overtime slots filtered by your certifications, and check certification expiration dates. When overtime opens up, in-department qualified people get texted first — if no one claims it, out-of-department qualified people get texted automatically. No more calling down the phone list.
Management & Configuration
Everything is configurable by management without touching code. Panel layouts, widget configurations, common problem libraries, recipes, schedules, departments, forklift operators, and the documentation system are all managed through admin pages. A full CMS (Content Management System) handles help articles and work instructions.
The core factory operations platform — communications, dispatch, scheduling, quality tracking, and management dashboards. Runs on standard server hardware with zero software licensing.
| Component | Details |
|---|---|
| Software Licensing | $0 per year. No per-seat, per-station, or per-user fees. No annual renewals. No vendor lock-in. |
| Primary Server (VM1) | Standard rack-mount or VM (Virtual Machine). Runs the ASP.NET application and database. Starts with embedded SQLite, designed for drop-in transition to SQL Server or PostgreSQL. Serves all factory floor stations. |
| Standby Server (VM2) | Hot failover via keepalived/VRRP (Virtual Router Redundancy Protocol) with floating IP (Internet Protocol) address. Automatic promotion if the primary fails. Continuous database replication via Litestream. |
| Offsite DR (Disaster Recovery) (VM3) | Geographic redundancy at a separate facility. Survives complete site loss. Same Litestream replication. |
| Database Administration | None required today. Starts with embedded SQLite — no DBA (Database Administrator), no separate server, automatic backups. Repository pattern architecture means a drop-in transition to SQL Server or PostgreSQL when scale demands it. Zero changes to any API (Application Programming Interface) or UI (User Interface). |
| Client Devices | Any device with a web browser — factory touchscreens, tablets, phones, desktops. No client software, plugins, or app store. |
| Network | Standard factory LAN (Local Area Network). Wi-Fi for mobile stations. No special infrastructure required. |
| Multi-Factory Scaling | One codebase, per-site configuration. Each factory runs independently on its own hardware with its own data. |
| Development | Built in C# — thousands of available developers worldwide. No proprietary tools or specialized training. |
NI (National Instruments) CompactDAQ-based forklift driver-assist platform with dual-monitor workstations, camera systems, health monitoring, and AI (Artificial Intelligence)-driven predictive maintenance. Per-forklift hardware costs plus the AI (Artificial Intelligence) Observer infrastructure.
| Component | Details |
|---|---|
| NI (National Instruments) CompactDAQ Chassis (per forklift) | cDAQ-9174 4-slot USB (Universal Serial Bus) chassis. ~$1,718 new. Pure C# integration via NI-DAQmx .NET API (Application Programming Interface). Zero NI (National Instruments) software licensing. |
| NI (National Instruments) Digital I/O (Input/Output) Module | NI (National Instruments)-9375 32-ch digital I/O (Input/Output). ~$973 new. Reads reverse, ignition, seat switch, buttons. Used modules available 50-80% below list via eBay watch + test bench qualification. |
| NI (National Instruments) Analog Input Module | NI (National Instruments)-9205 32-ch analog input. ~$1,763 new. Battery voltage, hydraulic pressure, motor temperature. Used: ~$538 on secondary market. |
| NI (National Instruments) Accelerometer Module | NI (National Instruments)-9234 4-ch IEPE (Integrated Electronics Piezo-Electric). ~$3,717 new. Impact/shock detection for damage logging and safety. |
| Cameras (per forklift) | Rear + side industrial cameras. IP (Internet Protocol) or USB (Universal Serial Bus). OpenCvSharp capture in the edge service. Standard industrial camera pricing. |
| Onboard PC (Personal Computer) (per forklift) | Industrial fanless PC (Personal Computer) running the C# edge service. Dual display output for two touchscreen monitors. |
| Dual Touchscreens (per forklift) | Monitor 1: passive safety display (cameras, health gauges). Monitor 2: interactive task dispatch and messaging. |
| Vision Processing | $0. OpenCvSharp (open-source OpenCV wrapper for C#) handles all camera capture, obstacle detection, and image processing. No NI (National Instruments) Vision license, no LabVIEW. Runs in the same C# edge service. |
| NI (National Instruments) Hardware Testing Bench | One cDAQ chassis + module set for qualifying used/eBay modules before production deployment. Also serves as the development platform. Eliminates risk from used purchases. |
| AI (Artificial Intelligence) Observer Primary (Node 4) | Dedicated hardware running a local 70B+ LLM (Large Language Model) for production analysis and procurement intelligence. New, warrantied hardware only. Estimated $5,000 - $10,000. |
| AI (Artificial Intelligence) Observer Standby (Node 5) | Warm standby for business continuity. Same LLM (Large Language Model) capability, promotes on primary failure. New, warrantied hardware only. Estimated $5,000 - $10,000. |
Used NI (National Instruments) modules purchased through eBay watches can save 50-70% on I/O (Input/Output) hardware. Every used module is validated through the testing bench before deployment. Production-critical controllers and AI (Artificial Intelligence) Observer hardware are always purchased new with warranty.
NI (National Instruments)-controlled automated ladle transfer between the Deck, Autopour 1, and Autopour 2. The hoist and track system moves molten metal on schedule, switches tracks automatically, and optimizes pour timing to reduce metal waste. A human operator monitors and can override at any point.
| Component | Details |
|---|---|
| NI (National Instruments) CompactDAQ Controller | cDAQ chassis with digital and analog I/O (Input/Output) modules controlling hoist motors, track switches, position encoders, and limit switches along the Deck–Autopour path. |
| Hoist Motor Control | NI (National Instruments) digital output modules driving VFDs (Variable Frequency Drives) for hoist raise/lower and traverse. Closed-loop position control via encoders ensures precise ladle placement at each pour station. |
| Automatic Track Switching | NI (National Instruments)-controlled actuators for hoist track junctions. System routes the ladle to the correct Autopour station based on the active heat schedule. Eliminates manual track switching. |
| Ladle Position Sensors | Limit switches, proximity sensors, and encoders at key positions: Deck pickup, track junction, Autopour 1 pour point, Autopour 2 pour point. NI (National Instruments) digital inputs confirm position before any movement. |
| Pour Optimization Software | Coordinates with heat schedule and Autopour status. Sequences ladle delivery to minimize idle time at pour stations. Reduces metal cooling and waste from late deliveries or missed timing windows. |
| Weight/Load Monitoring | NI (National Instruments) analog input from load cells on the hoist. Tracks metal weight throughout transfer. Detects abnormal weight loss (spillage) and triggers immediate stop. Data feeds pour yield analysis. |
| Spillage Prevention System | Controlled acceleration/deceleration profiles for hoist traverse. Speed limits through curves and at track switches. Tilt monitoring via NI (National Instruments) analog input. Prevents the sudden movements that cause molten metal spillage. |
| Safety Interlocks | Hardwired safety relays + NI (National Instruments)-monitored E-stop chain. Area clear sensors at pour positions. Automatic stop on any fault condition. Human override available at every station and at the main control panel. |
| Operator Override Station | Physical control panel at the Deck with manual hoist/traverse controls. Touchscreen display showing ladle position, weight, schedule, and system status. Operator can take manual control at any time. |
| Integration with Factory Server | C# edge service pushes ladle movement events, pour timing, weight data, and fault logs to the existing ASP.NET platform via REST (Representational State Transfer) API (Application Programming Interface). Real-time status visible on the Deck control panel via SignalR. |
This system directly reduces three major cost drivers: metal waste from mistimed pours and ladle cooling, equipment damage from manual track switching errors and sudden hoist movements, and spillage damage from uncontrolled acceleration. The AI (Artificial Intelligence) Observer analyzes transfer data over time to further optimize timing and flag mechanical wear before failure.
A lightweight, separate ASP.NET app on an external VPS (Virtual Private Server) that employees access from their phone or home computer. Personal calendars, overtime claiming, PTO (Paid Time Off) requests, and certification tracking — all authenticated with employee ID + PIN (Personal Identification Number).
| Component | Details |
|---|---|
| VPS (Virtual Private Server) Hosting | $5–$10/month. Basic cloud VPS (Virtual Private Server) from any provider. Minimal resource requirements — this is a lightweight read-heavy app. |
| Software Licensing | $0. Same open-source C# / ASP.NET stack as the factory server. Same zero-admin database. Same zero licensing. |
| Authentication | Employee ID + PIN (Personal Identification Number) login. Simple, no third-party identity provider required. Employees already have IDs in the system. |
| Personal Calendar | Each employee sees their scheduled shifts, approved vacation, plant holidays, and shutdown dates. Monthly calendar view with today highlighted. |
| Overtime Slot Claiming | Management posts open slots on the factory server. Portal shows slots filtered by the employee's certifications. Employee taps to claim. Eliminates the supervisor phone-call-down-the-list process entirely. |
| PTO (Paid Time Off) Request Submission | View PTO (Paid Time Off) balance, submit time-off requests, track approval status. Requests flow to management on the factory server with coverage-impact visibility. |
| Certification Status | Current certifications, expiration dates, training requirements. '30-day expiration' warnings keep compliance on track. |
| Data Sync | Factory server pushes roster, certifications, schedules, and calendar data to the Portal. Portal sends PTO (Paid Time Off) requests and overtime claims back. All outbound from factory — Portal never reaches into the factory network. |
| Domain / SSL (Secure Sockets Layer) | Optional custom domain (~$12/year). Free SSL (Secure Sockets Layer) via Let's Encrypt. Portal accessible from any phone browser — no app store, no install. |
Total Employee Portal cost: roughly $70–$130/year for hosting + domain. Provides every employee with phone access to their schedule, overtime opportunities, and PTO (Paid Time Off) management. The overtime claiming feature alone saves significant supervisor time — no more Friday afternoon phone lists.
AI (Artificial Intelligence) Business Intelligence — Offline, Safe, and Self-Funding
A dedicated AI (Artificial Intelligence) system observes production data on a completely separate machine. It never connects to or modifies live operations. It analyzes patterns, scans markets, and sends recommendations through the factory messaging system. A human always decides whether to act.
- Procurement Intelligence: Scans eBay, surplus dealers, and supplier markets 24/7 for below-market parts and materials. Documents every dollar saved.
- Production Analysis: Monitors heat cycles, pour delays, forklift response times, testing turnaround, and scheduling adherence. Flags anomalies automatically.
- Equipment Prediction: Tracks forklift health data across the fleet. Predicts hydraulic failures, battery end-of-life, and motor issues before they happen.
- Cost Monitoring: Watches energy rates, scrap metal pricing, supplier cost trends, and capital equipment auctions for savings opportunities.
- Redundant Architecture: Primary + standby observer pair ensures continuous intelligence. New, warrantied hardware only.
The procurement intelligence alone can save $50,000 - $200,000 per year at factory scale — making the entire system self-funding.
Every feature listed above is either working right now or has a detailed plan with architecture diagrams. Click any link above to see proof, or start with one of these: