Industrial Visibility Engineering

Your plant already has the data.
We get it to the floor.

Altiora Dynamics builds operator dashboards, edge data collection, and Ignition integrations that run entirely on your infrastructure. No cloud dependency, no proprietary licenses, no rip-and-replace.

PLANT STATE SIMULATOR — LINE 3 INTERACTIVE
Status
OPERATIONAL
Latency
12ms
OEE
87.4%
Press Speed — Bimodal Detection RUN
0 CPM1,842 CPM2,400 CPM

Drag the slider or toggle plant state — this mirrors the actual bimodal clustering and alarm-pipeline logic running on deployed systems.

The Altiora
Standard
<15s
From tag to screen, sensor to shift lead
100%
Runs on your own infrastructure
0
New software licenses added
30 days
To a complete visibility-gap map
What We Deliver

Outcomes first. Full stack underneath.

Each engagement starts from a question your plant can't answer today and ends with a system your own team can run.

01
🏭
See every line, live

Real-time OEE broken out by availability, performance, and quality, line by line and shift by shift. The end-of-shift number becomes one you can act on mid-shift.

OEE monitoring · shift trending · offline detection
02
⚡
Catch stops as they happen

Edge sensing classifies every line as running or idle within seconds, so unplanned stops are detected automatically instead of reported after the fact. Works on older lines without a PLC upgrade.

Edge collection · GPIO pulse counting · bimodal state detection
03
🌡️
Spot utility drift before it's downtime

Continuous monitoring of boilers, compressed air, and steam pressure, with health scoring and anomaly flags that surface a problem before someone happens to walk past it.

Utilities monitoring · plant health scoring · anomaly detection
04
🔗
Put your Ignition data anywhere

A secure bridge exposes your existing tags and historian to any screen, kiosk, or browser, without adding Ignition client licenses or touching your control logic.

Ignition WebDev · historian queries · OPC-UA
05
📊
Screens built for the floor

Touchscreen kiosks and wall-mounted displays designed for operators and shift leads: readable from across the aisle, self-refreshing, and usable without training.

Operator dashboards · kiosks · TV-wall scaling
06
📐
Answer questions your historian can't

Custom analytics on your own data, built around the questions your team actually asks: why a line underperforms on certain shifts, which conditions precede quality escapes, where capacity is hiding.

Python analytics · regime detection · quality scoring

Signal Path Architecture Explorer

Click a node to see the protocol, latency budget, and code for that layer. Ignition serves as the historian, OPC gateway, and API layer throughout.

🎛️
PLC / Field Sensors
Allen-Bradley · Siemens · Modbus TCP
📟
Raspberry Pi Edge
GPIO · RS-232/485
🔗
Ignition WebDev API
Auth JSON bridge
📊
Custom Web UI
NiceGUI · Streamlit
Proof of Work

Case Study: Multi-Line Plastics Manufacturing Plant

Client details generalized to protect confidentiality — no proprietary source or client-specific data is shown.

Industry: Plastics / Thermoform & Extrusion Facility: Multi-line production, Southeast US Engagement: Embedded plant engineering + dashboard buildout
The Situation

Line-level performance was tracked manually at shift change. OEE existed only as an end-of-shift number, utilities were monitored by walking the floor, and unplanned stops were reported by operators after the fact rather than detected automatically.

Technical Constraints

Ignition SCADA already held the tag data, but no operator-facing layer existed outside the native Ignition client. Any kiosk deployment needed to survive factory-floor conditions — dust, vibration, non-technical operators — without a proprietary client on every touchscreen.

Full-Stack Architecture
  • Raspberry Pi kiosks with GPIO pulse counting for press speed
  • Bimodal cluster analysis for automatic RUN / IDLE classification
  • Ignition WebDev REST bridge exposing tag historian data as authenticated JSON
  • NiceGUI dashboard rendered via iframe srcdoc injection to eliminate Quasar CSS scoping conflicts and refresh flicker
Outcomes
  • Manual walk-through cadence (30–60 min) → automated refresh under 15 seconds
  • End-of-shift OEE reporting → real-time, line-level, wall-mounted
  • Operator-reported stops → automatic bimodal-state alarm within seconds
<15s
Automated refresh vs. 30–60 min manual walk-throughs
Real-Time
Line-level OEE vs. end-of-shift reporting
Seconds
To automatic stop-detection vs. operator-reported
Before — Manual, Delayed
Shift Log — Line 3
07:00Startup OK
09:15Speed ~ok?
11:30Down 20min (unlogged)
14:00OEE — calc EOD
"Boiler seemed a little hot around noon — didn't write down temp." — handwritten note, actual shift log
After — Real-Time, Automated
Line 3 — Shift A● LIVE
87.4%
Overall Equipment Effectiveness
↔
Whiteboard + walk-throughsDrag to compareLive wall dashboard

You own everything we build.

Platform vendors make money by sitting between your plant and its data. Altiora is structured the opposite way: we set the system up, tune it, and support it, and your plant keeps every piece of it.

The continuity test: if Altiora disappeared tomorrow, every system we built would keep running, and your team would have the code and documentation to maintain it.
Your code

Every script, dashboard, and integration is delivered as readable, documented source and handed over at the end of the project.

Your data

Tag data stays on your network and in your Ignition historian. Nothing goes to an outside cloud unless you ask for it.

Your infrastructure

Systems run on your servers, your network segments, and your existing Ignition gateway, built to fit your OT security setup rather than work around it.

Your choice of support

Ongoing maintenance is available, never required. Your controls team or any capable integrator can pick up where we left off.

Visibility Audit

Know exactly where your plant is blind — in 30 days.

A fixed-scope audit of your current signal chain, from PLC to operator, that identifies unlogged downtime, latency gaps, and quick-win visibility fixes. No commitment beyond the audit.

🗺️
Signal-Path Map
A full map of your current SCADA/historian setup, Ignition or otherwise.
📉
Visibility Gap Report
Quantified breakdown of where you rely on manual logs vs. automated capture.
📋
Prioritized Recommendations
3–5 scoped fixes with rough effort and impact sizing — no vague roadmaps.
🖥️
Live Proof-of-Concept
A working dashboard walkthrough built from your actual, sanitized tag structure.
Format: Remote + optional 1-day on-site Fee: Fixed scope, quoted up front Deliverable: Written report + live demo
Map Your Visibility Gaps
The Founder

Built by an engineer who works the floor.

Altiora Dynamics was founded by Stephen Asher, a Georgia Tech–trained materials engineer who still works as a practicing plant engineer in multi-line manufacturing.

That matters because the hard part of plant visibility is rarely the software. It's knowing which signal actually means the line is down, which number a shift lead will trust, and what survives dust, vibration, and a 2am restart. Every system Altiora ships has run on a live production floor first.

Altiora is deliberately specialized: one accountable engineer from sensor to screen, with no handoffs between a hardware vendor, an integrator, and a dashboard shop. When something needs fixing, you talk to the person who built it.

🎓
Georgia Institute of Technology
B.S. Materials Science & Engineering
🏭
Practicing Plant Engineer
Systems built and run on a live, multi-line production floor
📡
Sensor to Screen
Edge hardware → Ignition → dashboards → analytics
Technology Stack
Hover a badge for how we use it. Click to jump there.
Python
NiceGUI
Streamlit
Ignition
OPC-UA
Raspberry Pi
GPIO
Plotly
FastAPI
PostgreSQL
WebDev API
Modbus TCP
Field Notes

Engineering Lab

Short, specific write-ups on real decisions from real deployments — not tutorials, postmortems.

NiceGUI · CSS
Why We Render NiceGUI Dashboards Inside an iframe srcdoc
What Quasar CSS scoping breaks on a plant-floor TV wall, and the injection pattern that fixes refresh flicker for good.
Coming soon
Signal Processing
Bimodal Clustering for Run/Idle Detection
A simpler alternative to threshold alarms for classifying machine state from noisy GPIO pulse data.
Coming soon
Ignition · REST
Designing an Ignition WebDev REST Bridge
Auth options, polling-interval tuning, and historian query patterns for exposing tag data as JSON.
Coming soon
Next Step

See your plant
in real time.

Whether you need one wall display, a full Ignition integration, or edge data collection on a line that has none, the first conversation is about what your plant can't see today.

See a Live Dashboard

A short, no-pitch walkthrough of a live dashboard on real (sanitized) tag data. Bring a rough sense of your PLC/SCADA setup.

View Capabilities
Ready to see it running on your tag data? See a Live Dashboard