Plant control-room platform
Plexus
The control nexus for plant operations — one real-time, role-gated dashboard for the whole shop floor.
Private · in production
The problem
A manufacturing plant ran on a sprawl of Excel files, kiosk PCs, chat messages, and tribal knowledge. The numbers existed, but no one had a single, trustworthy, real-time picture — and what an operator needs to see is not what a manager or an admin does. Plexus replaces that sprawl with one industrial control room, role-gated so each person sees exactly their view.
What it does
Plexus is a single web application that consolidates the shop floor into one dashboard: glance-able numbers on wall-mounted TVs for operators, configuration of thresholds, teams, quality loops and containment for managers, and control over roles and routing for admins.
Its modules are deliberately named like a control room rather than a SaaS menu — Mission Control, Plant Display, Shift Flow, Crew Scorecards, Andon, Quality Loop, Containment Zone, Paceboard, Product Blueprint, Crew Hub, and Core Settings. Status is never colour alone: it’s a colour, a dot, and a word — ACTIVE, CLOSING, AT LIMIT.
It’s built to be quietly dependable — quick to load, cheap to run, and simple to keep going, with a small companion device that raises urgent alerts even when nobody is at a screen. The whole thing wears an “industrial control-room” look: dense, sharp, and precise, with a single electric-lime accent.
Key features
Built into the system.
Big-screen plant displays
Glance-able shift KPIs on wall-mounted TVs — readable from across the floor, refreshing in near-real-time.
Shift flow & crew scorecards
Output, first-pass rate against target, and league tables per crew and production day — clarity that motivates without noise.
Andon & quality loops
Downtime and quality alerts, defect catalogues, and rework loops that close the gap between a problem and a fix.
Containment management
Containment runs and results with thresholds, evidence, and packing instructions — the intricate work, kept orderly.
Roles & access, by design
Every workspace is role-gated; admins control who sees what, and how alerts are routed.
Fast and dependable
Quick to load, cheap to run, and simple to operate — no fragile moving parts, so it just keeps working.
02 Inside the control room
One screen for the whole plant.
Glance-able numbers for the floor, configuration for managers, control for admins — dense, sharp, and real-time.
A private platform, built end to end.
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The tools, chosen with care.
How it’s built
What it runs on
Plexus was built for a specific manufacturing plant; this case study is kept client-neutral, with the client, location, and live data omitted. The visual above is rendered in Plexus’s own industrial-telemetry identity.
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