FactOS

Industry 4.0 Platform for Smart Manufacturing

FactOS is a Factory Operating System and Edge IoT Gateway that connects legacy and modern machines to track OEE, downtime, and production KPIs in real time.

FactOS Applications

The ultimate ecosystem for smart manufacturing digitization.

Smart Shopfloor Workflow

ERP LAYER

HR & Purchase

Manage workforce and procurement

Inventory

Real-time stock tracking

FACTOS LAYER

RM Management

Schedule production tasks

Production Planning

Optimize resource allocation

Production Execution

Live shopfloor monitoring

Maintenance

Preventive machine care

Quality

Strict quality control checks

FG Management

Finished goods handling

ERP LAYER

Sales Invoicing

Automated billing process

Dispatch

Logistics and delivery

Smart Shopfloor

Machines Digitized Under Our Process Digitization Ecosystem

Injection Moulding Machine
Extrusion Machine
Foam Moulding Machine
Die Casting Machine
Blow Moulding Machine
Press Shop Machine
Welding Machine
Assembly Machine

Highlights

Real-Time OEE

Monitor Availability, Performance and Quality in real time to improve manufacturing efficiency.

Automated Reports

Receive automated daily, weekly and monthly production reports for faster decision-making.

AI-Powered Insights

Identify patterns, potential issues and opportunities to reduce downtime and improve performance.

Universal Connectivity

Connect legacy and modern machines through our Industrial Edge IoT Gateway.

Real-time Dashboards & Reports

One platform. Full visibility. Data-driven decisions in real time..

FactOS real-time OEE metrics and production tracking dashboard
FactOS machine status, downtime analysis, and availability monitoring chart
FactOS shopfloor production output and cycle time analytics view
FactOS automated reporting and performance quality summary report

KPIs We Monitor

Track what matters most - Real-time KPIs that drive shopfloor performance and profitability

20+Critical KPIs tracked in real-time

Machine Performance

  • OEE (Overall Equipment Effectiveness)
  • Cycle Time
  • Downtime Tracking
  • Rejection Rate

Production Metrics

  • Production Output
  • Machine Utilization
  • Availability Rate
  • Performance Rate

Maintenance & Quality

  • Quality Rate / First Pass Yield
  • Process Parameters
  • MTBF (Mean Time Between Failures)
  • MTTR (Mean Time To Repair)

Need a custom KPI? We can build it.

Proven Impact: ROI You Can Measure

15-20%
OEE Improvement
25-30%
Downtime Reduction
10-15%
Quality Rejection Drop
The Hardware

Edge IoT Gateway

Industrial-grade hardware designed for the harshest shopfloor environments. Our proprietary gateway bridges the gap between legacy machines and modern intelligence.

Protocol Support

  • Modbus RTU/TCP
  • OPC-UA
  • MQTT
  • Ethernet/IP
  • Profinet
  • Euromap 77
  • & More

Key Features

  • • Edge Computing
  • • Local Data Buffering
  • • Over-the-Air (OTA) Updates
  • • Secure Encryption

Connectivity

  • • Wi-Fi / Ethernet
  • • 4G / 5G LTE
  • • RS485 / RS232
  • • Digital/Analog I/O
Dalnex Industrial Edge IoT Gateway hardware device for machine connectivity
Buyer & Engineering FAQ

FactOS Frequently Asked Questions

Engineering, integration, and operational answers for discrete plant leaders and automation engineers.

An edge IoT gateway is an industrial-grade hardware controller that interfaces directly with machine sensors, PLCs, and electrical signals to collect and process telemetry on the factory floor. FactOS uses its proprietary edge gateway to compute cycle times, machine states, and OEE locally with microsecond latency before securely transmitting encrypted operational metrics to the cloud.
FactOS calculates OEE in real time using the gold-standard formula: Availability × Performance × Quality. Availability measures actual operating time against planned production hours; Performance evaluates actual output against the ideal design cycle speed; and Quality tracks first-pass yield by dividing defect-free units by total parts produced.
Yes, FactOS is designed with universal machine connectivity for both modern CNC/PLC equipment and legacy machinery lacking digital interfaces. Using non-intrusive current transformers (CTs), optical proximity sensors, and digital I/O pulse counters, FactOS extracts live cycle counts and operational status without altering machine wiring or voiding manufacturer warranties.
A standard FactOS pilot deployment across 5 to 10 machines is completed within 3 to 7 business days. This timeline includes non-disruptive sensor mounting, edge gateway commissioning, Wi-Fi or Ethernet network configuration, and customized dashboard onboarding for plant managers and machine operators.
FactOS natively supports leading industrial protocols including Modbus TCP/RTU, OPC UA, MQTT, Ethernet/IP, Siemens S7, Profinet, and Euromap 77. It is deployed across discrete manufacturing assets such as plastic injection moulding machines, CNC machining centers, stamping presses, die casting units, extrusion lines, and automated assembly cells.
FactOS features local data buffering that safely logs all production data, timestamps, and alarm states directly on the edge gateway during network or internet outages. Once connectivity resumes, data automatically reconciles with zero data loss. All transmissions are safeguarded with TLS 1.3 encryption and enterprise role-based access control under Dalnex's ISO 27001:2022 certified management system.

Ready to Digitize?

Start your journey towards a smarter factory today.