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Read ArticleEnabling Human-Centric Industry 4.0 - From Shopfloors to Enterprise
TETHER Smart Manufacturing Platform (SMP) is a unified Industrial IoT, MES and analytics platform built to turn shopfloors data into operational intelligence. The platform contextualises raw shopfloor signals against orders, materials, routings and assets to deliver a comprehensive 360-degree view of a smart and connected factory performance. It delivers role-based workflows, guided operator experiences and persona-specific dashboards, enabling plant heads, operators, quality and maintenance teams to make informed decisions.
The platform operates alongside an existing MES, as the supervisory and visualisation layer, or directly as the MES itself, with selective modules. It extends beyond the shopfloor into supply chain operations, connecting inventory, warehouse operations and material movement to the same real-time data foundation. Its intelligent, API-first core can be deployed in the cloud, on-premises or in an edge-cloud hybrid environment and configured around your plant rather than built from scratch.
20%
Increase in Workforce Productivity
15%
Increase in Plant Capacity unlocked from same Asset Base
25%
Increase in First Time Right Quality
Building AI-Driven Sustainable Automation for Steel Industry
Three-Layer Design (ISA-95) built for IT and OT convergence
TETHER IIoT
Enterprise & Cloud (L4/L5) - Sitting above the plant, this layer turns factory data into enterprise intelligence. It benchmarks performance across sites through cross-plant analytics, enables digital twins and AI-driven insight.
TETHER FACTORY
Core MES/MOM (L3) - The execution heart of the platform, where production is planned, run and recorded. Track and trace, production monitoring, quality, OEE and maintenance operate through role-based workflows, giving production, quality and maintenance teams one contextualised single source of truth instead of three competing versions. Integration with SAP and other ERP, PLM and WMS systems keeps business systems and the shopfloor working from one shared reality.
TETHER EDGE
OT Integration (L0/L1/L2) - The connectivity foundation that instruments the shopfloor. It acquires data directly from PLCs, sensors, scanners and HMIs across 17+ industrial protocols, processing it locally through edge computing with low-latency, secure, store-and-forward delivery so no data is lost when the network drops.
Features of Smart Manufacturing Platform
Multi-Protocol Data Acquisition
Enterprise Integration
Industrial-Grade Security
Cognitive Manufacturing Intelligence
Modular & Multi-Tenant Deployment
Plant, line, asset and process models configured declaratively rather than hard-coded, compressing new line modelling and change cycles.
Microservices Architecture
Modular, independently deployable services with API-first design, enabling selective module activation and horizontal scaling without monolithic re-platforming.
Edge-Cloud Hybrid Topology
Distributed compute with local execution at the edge and analytics in cloud, addressing data residency, latency and OT network isolation requirements.
Use Cases
Connectivity & OT Integration
Connectivity & OT Integration
Connects any asset through OPC UA and various industrial protocols, with edge pre-processing and store-and-forward buffering normalising heterogeneous machine data into one common information model.
- Asset Protection: Connect legacy and modern equipment without replacement, directing capital toward capacity rather than compatibility.
- Zero Data Loss: Local buffering survives network interruption, so no production record is lost during outages.
Manufacturing Execution System
Manufacturing Execution System
Runs production digitally from order release to finished goods, with WIP tracking, UID serialisation, genealogy, guided operator stations and Poka-Yoke enforcement replacing paper-based control.
- Process Integrity: Error-proofing blocks out-of-sequence or unqualified operations, making correct execution the only possible execution.
- Instant Traceability: Complete lot lineage is captured at execution, not reconstructed later from paper records.
Quality Management
Quality Management
Monitors conformance in-line with Statistical Process Control, structured root cause analysis, non-conformance workflows and gauge calibration tracking, aligned to IATF 16949 requirements.
- Margin Protection: Process drift is caught before the batch moves on, reducing rework and scrap cost.
- Audit Readiness: Control plans, traceability and defect records remain permanently retrievable for customer and regulatory audits.
Asset Management & Maintenance
Asset Management & Maintenance
Monitors vibration, temperature and sensor telemetry against control limits, auto-triggering work orders, supported by downtime analysis, operator-led inspections and tool life tracking.
- Uptime Assurance: Intervention is scheduled before failure, so emergency repairs stop displacing planned maintenance work.
- Resource Optimisation: Spares, labour and tooling are consumed predictably against plan rather than reactively.
Intelligence & Analytics
Intelligence & Analytics
Delivers system-captured OEE, live KPI engines, Andon escalation, configurable dashboards, digital twin enablement and AI-driven predictive analytics via TEDAX and AIVA engines.
- Faster Decisions: Corrective action happens within the shift it belongs to, not in the next report.
- Accurate Attribution: Losses are measured by the system, so improvement effort targets the real constraint.
Warehouse & Materials
Warehouse & Materials
Enforces goods receipt, receiving inspection, RFID and QR identity mapping, system-assigned bin allocation and guided put-away, with live inventory visibility across WIP and stores.
- Inventory Accuracy: Physical and digital records stay synchronised continuously, eliminating periodic reconciliation exercises.
- Process Compliance: No inbound step can be bypassed, ensuring every material carries verified identity and history.
Sustainability
Sustainability
Monitors energy consumption with ISO 50001 aligned analytics, maps operator competency to qualified operations, and enables in-platform workflow design with conversational AI guidance.
- Attributable Efficiency: Energy use is linked to process context, making consumption reduction measurable and reportable.
- Reduced Dependency: Process changes are configured in-platform, removing reliance on custom development cycles.
Platform Architecture
An integrated framework connecting shopfloor assets to enterprise systems. At the shopfloor, TETHER EDGE handles IIoT gateway connectivity, field bus communication, data collection, local HMI, edge computing and security. TETHER FACTORY runs production scheduling, track and trace, quality inspection, maintenance, KPIs and dashboards. TETHER IIoT delivers big data processing and cross-plant intelligence, integrated bidirectionally with ERP, CMS, MIS, PLM and QMS across AWS and Azure.
Partners
