PLC & SCADA · AI Vision · Industrial IoT
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We engineer
AI vision inspection

Where PLC meets AI. MordeTech delivers world-class Siemens automation, machine vision, and smart factory systems — for manufacturers who refuse to lose.

150+
Projects Delivered
13+
Years Experience
99%
Uptime SLA
40%
Avg Cost Reduction
Signal chain · live streaming
01 Raw Material batch in
02 Machine 1420 rpm
03 Sensors 18 channels
04 PLC S7-1500
05 OPC UA secure tag map
06 Cloud Analytics MQTT · InfluxDB
07 AI Engine anomaly p=0.94
08 Actionable Insights act now
OEE: 94.7%
AI Defect Rate: 0.02%
The Real Cost

Old factories die from a thousand small cuts.

Every manufacturer knows the symptoms. Most never connect them to the real cause: an automation stack that was built for the 1990s, running a 2020s factory.

Quality
3–5%
defect escape rate

Defects that reach your customer.

Manual QC misses 3–5% of defects. They travel through your supply chain, reach the end customer, and return as warranty claims, production stoppages, and lost contracts. The damage compounds quietly — until it doesn't.

Downtime
₹4–10L
per breakdown event

The 2am phone call.

A machine fails. You call the maintenance team. By the time the part arrives and the line restarts, you've lost a full shift. Reactive maintenance costs 3–5× more than prevention. And it happens again next quarter.

Visibility
72 hrs
average decision lag

Managing a live factory with dead data.

Your SCADA shows yesterday. Your Excel sheet shows last week. You're making critical production decisions based on information that's already stale. By the time you see the problem, it's already a crisis.

There is a better way
The MordeTech Way

We built a different kind of automation company.

Not a system integrator that installs and disappears.

Not an AI startup that doesn't know a PLC from a HMI.

We sit at the intersection of deep OT expertise and modern AI.

We don't leave until your numbers move.

“13 years building automation systems for Indian manufacturers. AI-augmented. OT-native. We speak your plant floor language — and your CFO's.”

— Priyanka Morde, Founder & Director
MordeTech circuit tree
Module 01

AI Vision QC

Eyes that never blink. Deep learning models running at line speed — 94%+ defect reduction from day one.

ChallengeManual QC misses 3–5% of defects at line speed.
SolutionEdge inference on every part, with reject actuation via PLC.
Result4.0% → 0.06% escape rate; warranty claims down 70%.
PyTorch · NVIDIA Jetson · OpenCV
Module 02

Smart Automation

Reflexes in milliseconds. Siemens TIA Portal + SCADA systems that react before humans can see the problem.

ChallengeLegacy S5/S7-300 panels no one can service.
SolutionStaged migration to S7-1500 + WinCC Unified, live line kept running.
ResultZero production loss; 3 stoppages/year → 0.
Siemens S7-1500 · WinCC · OPC UA
Module 03

IIoT Intelligence

Your factory, live. Real-time OEE dashboards, predictive maintenance, and data that's always current.

Challenge72-hour lag between an event and the report.
SolutionOPC UA → MQTT → InfluxDB with Grafana OEE and energy views.
ResultOEE 61% → 83%; root cause visible in seconds.
MQTT · Grafana · InfluxDB · Edge AI
Predictive Maintenance

The failure announces itself. Five days early.

Vibration and temperature on the motor bearing, sampled continuously. The model learns the healthy signature, then flags the drift — and the work order is raised before the line stops.

Motor M-04 · Bearing NDE monitoring
Vibration
4.8 mm/s
Temperature
78 °C
Baseline dev.
+38%
Anomaly detected
Bearing wear · p=0.94
Phase 01
Sense

Vibration and temperature streamed from the motor and bearing over OPC UA.

Phase 02
Detect

The model compares live signature against the healthy baseline and scores the drift.

Phase 03
Alert

Alert to plant head and maintenance lead on WhatsApp with the failure mode named.

Phase 04
Schedule

Work order lands in the planned shutdown window. The line never stops unplanned.

Industry 4.0 Architecture

One factory. One nervous system.

Sensors to ERP without a manual hand-off anywhere in the chain. Every layer speaks a defined protocol, so the number on the director's screen is the number on the machine.

Layer 0
Machines
24 assets
Layer 1
Sensors
312 tags
Layer 2
PLCs
S7-1500
Layer 3
SCADA
WinCC Unified
Layer 4
MES
genealogy · OEE
Layer 5
ERP
orders · costing
—— OPC UA / Profinet —— MQTT to cloud ● bi-directional write-back
Smart Energy Monitoring

Every kilowatt, attributed to a machine.

Energy meters on each feeder stream into one dashboard, so consumption reads per asset, per shift, per tonne produced — and the anomaly is a machine name, not a monthly bill.

Plant load · live kW updating
MILL-1MILL-2PRESSKILNCOMPCHILLPACKUTIL
Specific energy
41.7 kWh / tonne
Idle-load recovered
₹18L / year
Live finding

KILN drawing 11% above baseline for the same throughput since the last shift change. Flagged to the energy manager automatically.

Industries

Pick your plant.

The stack is the same. What changes is the process it has to respect.

Cement Plants

Kiln stability without a firefight every shift.

Continuous process, huge inertia, and energy as the dominant cost. We instrument the kiln and mill circuit, then close the loop on setpoints so quality holds while specific energy falls.

−9%
kWh / tonne
+6 pts
kiln availability
Use cases
Kiln and mill circuit SCADA on WinCC Unified
Free-lime prediction from process tags
Baghouse and fan energy attribution per line
Vibration monitoring on mill gearboxes
Proven Results

Three plants. Transformed.

Real projects. Verifiable numbers. Here's exactly what we delivered — and how.

Tier-1 Supplier · Pune Automotive

From 4% defects to 0.06%. In 3 months.

Before
4.0%
→
After
0.06%

Warranty claims dropped 70% in Q1. System ROI achieved in 8 months.

AI Vision NVIDIA Jetson Siemens S7-1500
Press Shop · Aurangabad Manufacturing

From 61% OEE to 83%. In 6 months.

Before
61%
→
After
83%

Predictive alerts caught bearing failures 5 days early. Zero unplanned downtime in 6 months.

OPC UA IIoT Grafana Predictive Maint.
Utility Plant · Maharashtra Energy

15-year-old system. Zero downtime. 3 days.

Before
3/year
→
After
0/year

S5 → S7-1500 migration with zero production loss. ₹18L/year saved.

TIA Portal S7-1500 WinCC Unified Migration
Manufacturing intelligence · value chain
01
Production Line

Cycle times, rejects and stoppages captured at the source.

02
Data Collection

One tag model across PLCs, meters and quality stations.

03
Analytics

OEE, loss trees and root cause available per shift.

04
Optimization

Setpoints, schedules and maintenance windows corrected.

05
Profit Increase

Fewer rejects, fewer stoppages, lower energy per tonne.

Client Stories

In their own words.

Real plant managers, real engineering directors, real results.

“

MordeTech transformed our stamping line. Their AI vision system caught defects we were completely missing — our warranty claims dropped 70% in the first quarter. Delivered on time, within budget.

Rajesh Kulkarni
Plant Head · Tier-1 Automotive, Pune
“

We migrated our 15-year-old S5 system to S7-1500 with zero downtime. What seemed impossible was handled flawlessly. The new WinCC HMI has made our operators 40% more efficient.

Amit Deshpande
Engineering Director · Industrial Utility, Maharashtra
“

The OEE dashboard changed how we run our factory. We went from guessing at downtime causes to having real-time root cause data. OEE improved from 61% to 83% in 6 months.

Sneha Patil
VP Operations · Press Shop, Aurangabad
150+
Plants Automated
13+
Years Experience
99%
Uptime SLA
3
States Served
Your move

Your competition
isn't waiting.

Every day without AI vision, predictive maintenance, or real-time OEE costs more than the system would. Let's find out exactly how much — in a free, no-obligation, 2-hour plant assessment.

Response within 2 business hours  ·  No obligation  ·  Free plant assessment

PLC & SCADA · AI Vision · Industrial IoT
While you've been on this page
₹{{ lossText }} lost to downtime

We engineer
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Where PLC meets AI. MordeTech delivers world-class Siemens automation, machine vision, and smart factory systems — for manufacturers who refuse to lose.

150+
Projects Delivered
13+
Years Experience
99%
Uptime SLA
40%
Avg Cost Reduction
Signal chain · live streaming
01 Raw Material batch in
02 Machine 1420 rpm
03 Sensors 18 channels
04 PLC S7-1500
05 OPC UA secure tag map
06 Cloud Analytics MQTT · InfluxDB
07 AI Engine anomaly p=0.94
08 Actionable Insights act now
OEE: 94.7%
AI Defect Rate: 0.02%
The Real Cost

Old factories die from a thousand small cuts.

Every manufacturer knows the symptoms. Most never connect them to the real cause: an automation stack that was built for the 1990s, running a 2020s factory.

Quality
3–5%
defect escape rate

Defects that reach your customer.

Manual QC misses 3–5% of defects. They travel through your supply chain, reach the end customer, and return as warranty claims, production stoppages, and lost contracts. The damage compounds quietly — until it doesn't.

Downtime
₹4–10L
per breakdown event

The 2am phone call.

A machine fails. You call the maintenance team. By the time the part arrives and the line restarts, you've lost a full shift. Reactive maintenance costs 3–5× more than prevention. And it happens again next quarter.

Visibility
72 hrs
average decision lag

Managing a live factory with dead data.

Your SCADA shows yesterday. Your Excel sheet shows last week. You're making critical production decisions based on information that's already stale. By the time you see the problem, it's already a crisis.

There is a better way
The MordeTech Way

We built a different kind of automation company.

Not a system integrator that installs and disappears.

Not an AI startup that doesn't know a PLC from a HMI.

We sit at the intersection of deep OT expertise and modern AI.

We don't leave until your numbers move.

“13 years building automation systems for Indian manufacturers. AI-augmented. OT-native. We speak your plant floor language — and your CFO's.”

— Priyanka Morde, Founder & Director
MordeTech circuit tree
Module 01

AI Vision QC

Eyes that never blink. Deep learning models running at line speed — 94%+ defect reduction from day one.

ChallengeManual QC misses 3–5% of defects at line speed.
SolutionEdge inference on every part, with reject actuation via PLC.
Result4.0% → 0.06% escape rate; warranty claims down 70%.
PyTorch · NVIDIA Jetson · OpenCV
Module 02

Smart Automation

Reflexes in milliseconds. Siemens TIA Portal + SCADA systems that react before humans can see the problem.

ChallengeLegacy S5/S7-300 panels no one can service.
SolutionStaged migration to S7-1500 + WinCC Unified, live line kept running.
ResultZero production loss; 3 stoppages/year → 0.
Siemens S7-1500 · WinCC · OPC UA
Module 03

IIoT Intelligence

Your factory, live. Real-time OEE dashboards, predictive maintenance, and data that's always current.

Challenge72-hour lag between an event and the report.
SolutionOPC UA → MQTT → InfluxDB with Grafana OEE and energy views.
ResultOEE 61% → 83%; root cause visible in seconds.
MQTT · Grafana · InfluxDB · Edge AI
Predictive Maintenance

The failure announces itself. Five days early.

Vibration and temperature on the motor bearing, sampled continuously. The model learns the healthy signature, then flags the drift — and the work order is raised before the line stops.

Motor M-04 · Bearing NDE monitoring
Vibration
4.8 mm/s
Temperature
78 °C
Baseline dev.
+38%
Anomaly detected
Bearing wear · p=0.94
Phase 01
Sense

Vibration and temperature streamed from the motor and bearing over OPC UA.

Phase 02
Detect

The model compares live signature against the healthy baseline and scores the drift.

Phase 03
Alert

Alert to plant head and maintenance lead on WhatsApp with the failure mode named.

Phase 04
Schedule

Work order lands in the planned shutdown window. The line never stops unplanned.

Industry 4.0 Architecture

One factory. One nervous system.

Sensors to ERP without a manual hand-off anywhere in the chain. Every layer speaks a defined protocol, so the number on the director's screen is the number on the machine.

Layer 0
Machines
24 assets
Layer 1
Sensors
312 tags
Layer 2
PLCs
S7-1500
Layer 3
SCADA
WinCC Unified
Layer 4
MES
genealogy · OEE
Layer 5
ERP
orders · costing
—— OPC UA / Profinet —— MQTT to cloud ● bi-directional write-back
Smart Energy Monitoring

Every kilowatt, attributed to a machine.

Energy meters on each feeder stream into one dashboard, so consumption reads per asset, per shift, per tonne produced — and the anomaly is a machine name, not a monthly bill.

Plant load · live kW updating
MILL-1MILL-2PRESSKILNCOMPCHILLPACKUTIL
Specific energy
{{ kwhText }} kWh / tonne
Idle-load recovered
₹18L / year
Live finding

KILN drawing 11% above baseline for the same throughput since the last shift change. Flagged to the energy manager automatically.

Industries

Pick your plant.

The stack is the same. What changes is the process it has to respect.

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Use cases
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Proven Results

Three plants. Transformed.

Real projects. Verifiable numbers. Here's exactly what we delivered — and how.

Tier-1 Supplier · Pune Automotive

From 4% defects to 0.06%. In 3 months.

Before
4.0%
→
After
0.06%

Warranty claims dropped 70% in Q1. System ROI achieved in 8 months.

AI Vision NVIDIA Jetson Siemens S7-1500
Press Shop · Aurangabad Manufacturing

From 61% OEE to 83%. In 6 months.

Before
61%
→
After
83%

Predictive alerts caught bearing failures 5 days early. Zero unplanned downtime in 6 months.

OPC UA IIoT Grafana Predictive Maint.
Utility Plant · Maharashtra Energy

15-year-old system. Zero downtime. 3 days.

Before
3/year
→
After
0/year

S5 → S7-1500 migration with zero production loss. ₹18L/year saved.

TIA Portal S7-1500 WinCC Unified Migration
Manufacturing intelligence · value chain
01
Production Line

Cycle times, rejects and stoppages captured at the source.

02
Data Collection

One tag model across PLCs, meters and quality stations.

03
Analytics

OEE, loss trees and root cause available per shift.

04
Optimization

Setpoints, schedules and maintenance windows corrected.

05
Profit Increase

Fewer rejects, fewer stoppages, lower energy per tonne.

Client Stories

In their own words.

Real plant managers, real engineering directors, real results.

“

MordeTech transformed our stamping line. Their AI vision system caught defects we were completely missing — our warranty claims dropped 70% in the first quarter. Delivered on time, within budget.

Rajesh Kulkarni
Plant Head · Tier-1 Automotive, Pune
“

We migrated our 15-year-old S5 system to S7-1500 with zero downtime. What seemed impossible was handled flawlessly. The new WinCC HMI has made our operators 40% more efficient.

Amit Deshpande
Engineering Director · Industrial Utility, Maharashtra
“

The OEE dashboard changed how we run our factory. We went from guessing at downtime causes to having real-time root cause data. OEE improved from 61% to 83% in 6 months.

Sneha Patil
VP Operations · Press Shop, Aurangabad
150+
Plants Automated
13+
Years Experience
99%
Uptime SLA
3
States Served
Your move

Your competition
isn't waiting.

Every day without AI vision, predictive maintenance, or real-time OEE costs more than the system would. Let's find out exactly how much — in a free, no-obligation, 2-hour plant assessment.

WhatsApp Us Now Call +91 94040 30215

Response within 2 business hours  ·  No obligation  ·  Free plant assessment