Three data silos.
One source of truth.

Three systems. Three truths.

Gneuß is a successful mid-sized company in plastics processing with an IT landscape that grew over the years. Three worlds lived side by side: the ERP (order situation, stock levels), the machine data (production output, downtime), and quality assurance (measurement records, complaints). Each world only knew itself.

Complaints were analysed after the fact. More often than not it took weeks to find out: on which machine? In which shift? With which material? The answers sat in three systems and had to be pieced together by hand.

One integration layer. Four modules.

We replaced nothing. We connected. A new integration layer reads from the ERP, the machine controls and the QA system, normalises the data and provides one unified view, per order, per machine, per shift.

• Data connectors to the ERP (ProAlpha), machines (OPC UA) and QA system
• Central data hub with full history (PostgreSQL + time series)
• Web dashboard for shift leaders, quality management and senior management
• Complaint workflow with automatic root-cause analysis from the historical data

The solution runs on-site at Gneuß, on their own hardware. We delivered training, handed over documentation, and the in-house IT team has run operations themselves ever since. It's a typical example of our custom software development.

Complaints without the detective work.

Within six months of go-live: complaint handling time down from three weeks to four days. The complaint rate itself fell by 40%, because patterns became visible early and could be corrected before they turned into a grievance.

• −40% complaints within 12 months
• −85% handling time for complaint analysis
• 0 manual double entry between the systems
• ROI in < 14 months (calculated without avoided reputational damage)