It covers much of what plants actually buy an MES for — plant hierarchy, KPIs, alarms, shift handover, maintenance — without the scope and implementation timeline of a full MES programme. If your requirement is genuine order-to-batch genealogy across an enterprise, a traditional MES is the right tool. If it is visibility, discipline and decision speed on the floor, SyncPlant gets there faster.

Does SyncPlant require IndustrialBridge?

Not strictly. SyncPlant is Tier 02 of the TA Factory stack and IndustrialBridge is the Tier 01 data layer that normally feeds it, but SyncPlant can take data from an existing historian or database instead. Deploying both is the common path because the data layer is usually the missing piece.

Can SyncPlant run without internet access?

Yes. It deploys on-premise on the plant LAN. No plant data needs to leave the site and no cloud service is required for it to operate.

How are KPIs defined — is that a development task?

KPIs are formula-driven and configured, not coded. You define the calculation and the red/amber/green thresholds against the plant hierarchy, which means a process engineer can add or change a KPI without a software release.

Does it include maintenance management?

Yes. SyncPlant includes a CMMS module covering equipment registers, QR-coded asset tags and maintenance workflows, so maintenance history sits against the same equipment hierarchy as production data rather than in a separate system.

How long does a SyncPlant deployment take?

A pilot deployment is typically 6 to 8 weeks from start to live use, because the platform is configured rather than custom-built. Scope, data availability and plant network access are what usually move that number.

TA-FACT · TIER 02 · PLATFORM

The smart-manufacturing platform

SyncPlant
Make the plant legible.

The smart-manufacturing platform that sits on top of IndustrialBridge and turns clean data into a complete operational picture. Plant hierarchy with QR-tagged equipment, formula-driven KPIs, multi-level alarms, electronic logbook, CMMS, tablet log, and role-based access — 11 integrated modules, one source of truth.

Request a demo Back to TA Factory

PLANT · LINE 2 · MILL_2LIVE · 5s refresh

OEE

84.3%

Target 82

MTBF

42 h

Target 60

Yield

97.1%

Target 96

Energy / unit

2.8

Target 2.4

OEE · LAST 60 MINUTES

84.3%

Mill 2 bearing temp HiHi — 87.2°C14:31

Energy / unit drift — 6 min14:25

11 modulesOne integrated platform

QR-taggedEvery machine, scan-to-detail

60s / 2sKPI & alarm evaluation

6 rolesAdmin → Operator access control

The role

Tier 02 — built on IndustrialBridge, ready for the AI tier above

SyncPlant is the platform tier of the TA Factory stack. It assumes IndustrialBridge underneath, providing clean and reliable tag data. It produces structured operational artifacts that the TruAdaptiv Copilot tier consumes directly. Every dashboard, KPI formula, alarm threshold and equipment record you build here directly powers the next tier.

Platform modules

11 integrated modules — pick what you need, scale when ready

01 · HIERARCHY

Plant hierarchy & QR codes

Plant → Area → Line → Equipment → Component. Every machine carries OPC tag mappings, live values, history, and a printable QR. Technicians scan and see the asset instantly.

02 · KPIs

Formula-driven KPI engine

OEE, MTBF, MTTR, yield, throughput, energy — defined as formulas referencing OPC tags. Evaluated every 60 seconds with Red/Amber/Green status and drill-down.

03 · ALARMS

Four-mode alarm engine

Digital, Hi/Lo, HiHi/LoLo, and Rate-of-Change alarms. Evaluated every 2 seconds. Full acknowledge-and-clear lifecycle with audit log.

04 · DASHBOARDS

Dashboard designer

Eight widget types — KPI cards, trend charts, gauges, alarm panels, equipment status, custom HTML. Live refresh over SignalR. Full-screen on a 55″ TV for permanent floor display.

05 · LOGBOOK

Electronic logbook

Replaces paper handovers with structured workflow: outgoing operator submits entries, incoming accepts, supervisor signs off. Searchable, signed, audit-ready.

06 · CMMS

Maintenance management

Work orders with interactive checklists that validate technician readings against min/max limits. PM schedules auto-generate work orders when due. Spare-part tracking included.

07 · SHOPFLOOR

Tablet shopfloor log

Tablet-optimised interface for production-run tracking, categorised rejections and downtime across 9 categories. Designed for operators with gloves on.

08 · ENERGY

Energy allocation

Allocate shared utility energy (compressors, chillers, boilers) across machines by Fixed Percent, Run Hours or Capacity. Reveals true energy-per-unit cost.

09 · REPORTS

Scheduled reports

Visual report designer with multi-level grouping, calculated fields, parameterised SQL. Auto-deliver to email or shared drive on schedule.

10 · ACCESS

Six-role access control

Admin, Plant Manager, Supervisor, Technician, Operator, HQ Viewer. Tabs and actions gated per role. SSO-ready.

11 · PROTOCOLS

Native protocol support

OPC-UA, Modbus TCP/RTU, and relay/digital I/O — even the oldest machines come online. Inherits the bi-directional capability from IndustrialBridge.

Before vs after

What changes when SyncPlant is the platform layer

Capability

Before

With SyncPlant

Asset records

Spreadsheets, scattered docs

Hierarchy with QR, scan-to-detail

KPIs

Monthly reconciled in Excel

Live, formula-driven, RAG status

Alarms

SCADA-only, no audit

4-mode engine with full ack lifecycle

Logbook

Paper register, context loss

Electronic, signed, audit-ready

Maintenance

Reactive, breakdown-driven

PM schedule + work orders + spare tracking

Energy cost

Plant-level only

Per-machine, allocated correctly

Deployment

Built to scale module-by-module — and into the AI tier above

SyncPlant is modular by design. Most plants start with one line, one KPI dashboard, one CMMS workflow — and expand as trust compounds. Every artifact built here is ready to be consumed by TruAdaptiv Copilot in Tier 3.

Configured

Line-by-line

Configure to one line: KPIs, dashboards, CMMS, alarms. Operator training in parallel. Same platform, scale to the rest.

On the LAN

Infrastructure

Runs on plant LAN or private cloud. Pairs with IndustrialBridge below, TruAdaptiv Copilot above — all stay inside your perimeter.

11 modules

Modular adoption

Pick what your plant needs. Most start with hierarchy + KPIs + alarms + dashboards. Layer in CMMS, energy, logbook as confidence compounds.

AI-ready

Powers Tier 3

The structured artifacts SyncPlant produces — KPIs, alarms, maintenance history, logbook entries — are exactly what TruAdaptiv Copilot consumes.

Make the plant legible — and ready for the next tier

SyncPlant is ready to deploy as the platform layer of your TA Factory journey. Book a discovery call to walk through the modules and scope a deployment.

Request a demo See Tier 3 · Copilot →

Questions we get asked

Common questions

Is SyncPlant an MES?: It covers much of what plants actually buy an MES for — plant hierarchy, KPIs, alarms, shift handover, maintenance — without the scope and implementation timeline of a full MES programme. If your requirement is genuine order-to-batch genealogy across an enterprise, a traditional MES is the right tool. If it is visibility, discipline and decision speed on the floor, SyncPlant gets there faster.
Does SyncPlant require IndustrialBridge?: Not strictly. SyncPlant is Tier 02 of the TA Factory stack and IndustrialBridge is the Tier 01 data layer that normally feeds it, but SyncPlant can take data from an existing historian or database instead. Deploying both is the common path because the data layer is usually the missing piece.
Can SyncPlant run without internet access?: Yes. It deploys on-premise on the plant LAN. No plant data needs to leave the site and no cloud service is required for it to operate.
How are KPIs defined — is that a development task?: KPIs are formula-driven and configured, not coded. You define the calculation and the red/amber/green thresholds against the plant hierarchy, which means a process engineer can add or change a KPI without a software release.
Does it include maintenance management?: Yes. SyncPlant includes a CMMS module covering equipment registers, QR-coded asset tags and maintenance workflows, so maintenance history sits against the same equipment hierarchy as production data rather than in a separate system.
How long does a SyncPlant deployment take?: A pilot deployment is typically 6 to 8 weeks from start to live use, because the platform is configured rather than custom-built. Scope, data availability and plant network access are what usually move that number.