Bespoke L3 applications
Tracking, dispositioning, yard management, shift reporting, certificate generation — the modules your chosen platform priced out of scope.
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Advisory, delivery and the people who know the domain.
Four service lines, all pointed at the same problem: metals plants run on decisions that software should be making better, and most software does not understand metals.
Service 01
IT Consultancy
Independent advice from people who have been the customer, the implementer and the product owner — often on the same programme.
Most MES programmes do not fail on technology. They fail because the scope was drawn by someone who had never watched a shift handover, or because a platform was chosen before anyone agreed what Level 3 was supposed to own. We help you get those two things right before you spend the money.
Typical engagements
MES / MOM maturity assessment
Where you actually are against ISA-95, and the three gaps that matter most.
Vendor selection & RFP support
Requirement sets written in mill language, scored without vendor theatre.
Build vs. buy analysis
Honest, including the cases where the honest answer is "buy, and not from us".
Integration & data architecture
What lives at L2, what lives at L3, what belongs in ERP — and who owns each field.
Programme recovery
A second opinion on an implementation that has stopped moving.
One vocabulary between the line and the office
Service 02
Digital Transformation in Manufacturing
Industry 4.0 without the poster. Connect the line, make the data trustworthy, then automate the decisions that cost real money.
Most plants already have more data than they use. The problem is that the caster system, the mill system and the weighbridge each call the same piece of steel something different — so nobody trusts a number that crosses a boundary. That is the first thing we fix.
- OT/IT convergence — unified namespace, contextualised, replayable
- Shop-floor data capture — the manual steps that still run on paper and clipboards
- Traceability — genealogy that survives a customer complaint 14 months later
- OEE and downtime analytics — with reasons operators will actually enter
- Digital twin and simulation pilots — scoped to answer one question, not to impress a board
PHASE 01
Connect
Get signals off the line reliably and put them in one place with one naming convention. Usually 6–10 weeks per area.
PHASE 02
Trust
Reconcile against physical counts and lab results until the numbers stop being argued about in the morning meeting.
PHASE 03
Decide
Only now automate: scheduling, yield decisions, quality dispositioning, energy. This is where the money is.
Service 03
Software Development Services
Industrial software has to survive a plant: 24/7 operation, unreliable networks, users wearing gloves, and a change window that opens twice a year. We build for that.
Legacy modernisation
Oracle Forms, VB6, Delphi and 20-year-old C on a machine nobody wants to reboot. Migrated incrementally, with the old system still running.
Interfaces & middleware
L2 ↔ L3 ↔ ERP message handling with configurable field mapping, replay, and a dead-letter queue you can actually read.
Simulators & test harnesses
Generate realistic L2/L3 traffic so you can test the new system before the line is available — not during commissioning weekend.
3D & visualisation
Yard and stockyard visualisation, stacking rules, crane routing — rendered so a planner can see the constraint instead of reading it.
CI/CD & release management
Semantic versioning, per-customer release trains, database migrations handled properly. Upgrades stop being an event.
Our working stack
Chosen for total cost of ownership over a 10-year plant lifecycle, not for what is fashionable this year.
Python · DjangoPostgreSQLReact · TypeScript
Kafka · CeleryLiquibaseDocker
AzureThree.jsOPC-UA · MQTT
Service 04
Expert Resources — Metals Domain
The hardest thing to hire in this industry is not a developer. It is someone who understands why a heat cannot simply be re-sequenced, and can also write the specification.
PSI Metals specialists
Functional and technical consultants with hands-on PSImetals implementation experience — Planning, Production, Quality and Logistics modules.
MES business analysts & solution architects
People who can sit with a caster foreman in the morning and write a workable functional spec in the afternoon.
Scheduling & planning specialists
Melt shop, hot mill, cold mill and finishing-line scheduling logic — plus the S&OP layer above it.
How we place people
- Domain-screened, not keyword-screened — every candidate is interviewed by someone who has run a plant system
- On-site, hybrid or remote across EU, UK and India time zones
- Staff augmentation or managed workstream — you keep control, or we take the outcome
- Knowledge transfer built in so your team is not dependent on ours when we leave
Need a PSI Metals expert this quarter?
Tell us the module, the phase and the location. We will come back with availability rather than a brochure.
Send a resource request
Design Partner Program · open
Prefer to start with the product?
DigiPlantMES is our own MES for metals — and we are selecting a small number of design partners to shape it against real operations.