Machine monitoring and production tracking
Machine monitoring for factories, starting with the machines you already have.
See what every machine produced this shift, when it stopped and why, without walking the floor. Karyo sets up production and downtime tracking in three stages: operators record it at the machine, then readings come in automatically, then machines connect live. You start with no hardware and move up only when the numbers justify it.
- First stage typically live in 2–3 weeks
- Any machine, any age
- On site across India
The problem
Most factories learn what the machines did at the end of the day, if at all.
Output is counted at the end of the shift and written in a register. A machine that stood idle for forty minutes waiting for material shows up nowhere. Breakdowns are remembered, small stops are not, and by month end nobody can say which machine is holding the plant back or what a unit really costs in power.
The usual answer is an expensive monitoring project with sensors on every machine.
We start with the records, prove which numbers matter, and only then connect the machines that are worth connecting.
Three stages
From a phone at the machine to a live plant dashboard.
Each stage builds on the last, in the same system, so nothing is thrown away when you move up. You decide when to move, with the records in front of you.
Operators log it at the machine
Start, stop, output and downtime with a reason, entered on a phone or tablet at the machine. No hardware change, no wiring, no downtime to install. Works on any machine, any age, from a decades-old lathe to a new packing line.
Readings taken automatically
We pull figures from what the plant already produces: weighbridges, energy meters, counters and controller exports. Small hardware is added only where a reading is not already available. Operators stop typing numbers the plant already measures.
Machines connected directly
A direct connection to PLCs and sensors, over protocols such as Modbus and OPC UA, for live status, alerts when a machine stops or drifts, and a maintenance history for every machine, all on one dashboard.
Start at stage one with no hardware. Move a machine up only when its numbers justify the cost.
What you see
Production tracking an owner can read on a phone.
The point of machine data is decisions: which line to fix first, whether to add a shift, when to service a machine. These are the views every plant gets, shaped around your machines, shifts and products.
Output per shift
What each machine and each shift produced, against what it was planned to produce, without waiting for a supervisor's register.
Downtime and its reasons
Every stop with its cause: no material, changeover, breakdown, no operator, power. Repeated causes stand out within weeks.
Machine utilisation
How many hours each machine actually ran, so decisions on a new machine or an extra shift rest on records, not impressions.
Energy per unit
Power used against output, by machine and by shift, once energy meters are read at stage two.
Maintenance due
Running hours and service history per machine, with reminders before the next service instead of after the next breakdown.
One view for the owner
The whole floor on a phone: what is running, what has stopped and why, and how today compares with last week.
Connected to the business
Machine data that sits next to orders, stock and dispatch.
A machine dashboard on its own tells you a machine stopped. Connected to your CRM and ERP, it tells you which customer order is now late, which raw material ran out and what the stoppage cost.
It also fits a business going digital one step at a time. A plant that still runs its accounts in Tally and its orders on paper can start with machine records alone and add the rest later, at the pace that suits it.
Who it is for
Built for plants without an IT department.
If you run machines and track their output on paper, Excel or memory, this is for you, whatever you make.
Small and mid-size factories
Machining, fabrication, plastics, printing and assembly units where output is still counted at the end of the shift.
Mills and processing plants
Rice, flour, oil, textile and similar mills where a stopped line or a wet batch costs money every hour.
Packaging units
Lines where changeovers, jams and material shortages decide the day's output.
Family-run plants
Plants that have run on the owner's experience for decades and want the next generation to have the same view in writing, starting with no change to the machines.
How it works
On site, in writing, at every step.
Plant work starts with a visit, never a guess. Scope, price and the go-live date are fixed in a written proposal before work begins.
| Step | What happens | What you receive |
|---|---|---|
| 01 · Site survey | We walk the floor, list every machine, see what each one already measures, and agree which numbers matter most to you. | A written scope, fixed quote and go-live date. |
| 02 · Set up stage one | Recording screens shaped around your machines, shifts and downtime reasons, with the owner's dashboard on top. | A working system, typically live in two to three weeks. |
| 03 · Train on the floor | Operators and supervisors are trained at the machine, on the job, in English and Hindi. | Every shift recording from day one. |
| 04 · Review and move up | After a few weeks of records we review the numbers with you and recommend which machines, if any, justify stage two or three. | A clear case for the next stage, or a reason to stay where you are. |
| 05 · Host and look after it | Hosting, backups, updates and support under the annual maintenance contract, with machine dashboard monitoring if you want it. | A monthly report on uptime, changes and requests. |
After go-live the system is hosted and looked after under an annual maintenance contract. If you have no one free to watch the dashboards, our managed operations service can do it for you.
Who builds it
Built by a team that runs real operations.
Karyo is built by TUD Innovations, the company behind Kenro, the software proven on a working workshop floor and running at a pre-owned car showroom in Delhi. We show what our systems do, and publish results only once they have run long enough to stand behind.
Machine monitoring: common questions
Do we need to buy new machines or sensors to start?
No. The first stage needs no hardware at all. Operators record start, stop, output and downtime on a phone or tablet at the machine, so it works on any machine of any age. Hardware is added only at the second or third stage, and only where the numbers show it is worth it.
Our machines are old. Will this still work?
Yes. Stage one does not connect to the machine, so age and make do not matter. For stage two we read what the plant already produces, such as counters, energy meters and weighbridges, which most older plants have. A direct controller connection at stage three depends on the machine, and we confirm it on site before quoting.
What is OEE, and can a small factory use it?
OEE, or overall equipment effectiveness, combines how long a machine actually ran, how fast it ran and how much good output it made. A small factory can track it from stage one, because the inputs are the same start, stop, output and downtime records an operator logs. You see it per machine and per shift, without a consultant or a large software licence.
How long does it take to get started?
The first stage is typically live in two to three weeks. The written proposal fixes the date before work begins.
Does the machine data connect to our ERP and Tally?
Yes. Machine output, downtime and energy readings sit in the same system as production, stock and dispatch, so a production order shows what was made on which machine. If you already use Tally, it stays your books.
Which controllers and protocols can you connect to?
At stage three we connect to PLCs and sensors over standard industrial protocols such as Modbus and OPC UA. What is possible depends on your controllers, so we check every machine on site and write the connection plan into the proposal.
Do you offer this outside India?
No. Plant and machinery work is offered in India only, because it needs our team on site to survey the machines, set up the recording points and train operators. Websites, SEO and portals are delivered remotely and are available anywhere.
Contact
Tell us about your plant.
How many machines, how many shifts, what you record today and what you wish you knew. We will arrange a site visit and send a written proposal with a fixed quote.