Industrial IoT (IIoT) Development
ClickMasters builds IIoT systems for manufacturing and industrial B2B companies across the USA, Europe, Canada, and Australia. OPC-UA and Modbus TCP connectivity to PLCs, CNCs, and legacy industrial controllers. Real-time OEE dashboards with downtime categorisation and shift reporting. Ignition SCADA with MQTT Sparkplug B to cloud. Edge computing with AWS Greengrass and NVIDIA Jetson. IT/OT network segmentation per ISA/IEC 62443.
Years Experience
Projects Delivered
Client Satisfaction
Support Available
OPC-UA The Standard for Industrial Connectivity
OPC-UA (OPC Unified Architecture IEC 62541) is the primary vendor-neutral, platform-independent, secure protocol for industrial machine communication. Before OPC-UA, industrial connectivity required vendor-specific proprietary protocols or OPC Classic (Windows COM/DCOM only, poor security). OPC-UA provides built-in authentication, authorisation, and TLS encryption, runs on Linux gateways and cloud services (not just Windows), and includes a semantic information model where data is described with context and structure rather than raw register values. MQTT Sparkplug B extends OPC-UA data to cloud platforms like AWS IoT Core Ignition SCADA with the MQTT module publishes OPC-UA tag values as Sparkplug B payloads, making factory floor data available to cloud analytics pipelines in real time.
OEE = Availability × Performance × Quality
OEE (Overall Equipment Effectiveness) = Availability x Performance x Quality. Availability: actual running time / planned production time. Performance: actual output rate / rated output rate. Quality: good parts / total parts produced. World-class OEE is typically 85%+. The global manufacturing average is approximately 65%. Low Availability indicates unplanned downtime or long changeovers. Low Performance indicates slow running or minor stoppages. Low Quality indicates process parameter issues causing defects. Real-time OEE monitoring with automatic downtime categorisation (operators select the loss reason on an HMI) makes losses visible and drives focused improvement. Moving from 65% to 75% OEE on a production line can increase output by 15% without adding equipment or headcount.
Industrial IoT Services We Deliver
ClickMasters operates as a full-stack industrial iot partner. Our team handles every layer of the software delivery lifecycle — product strategy, UI/UX design, backend engineering, cloud infrastructure, QA, and ongoing support.
OPC-UA Machine Connectivity
Connect PLCs and industrial controllers to the cloud: OPC-UA client (IEC 62541 vendor-neutral secure protocol connecting Siemens S7, Allen-Bradley, Beckhoff, Fanuc, Mitsubishi), Modbus TCP/RTU (legacy protocol in older equipment Ethernet or RS-485 serial), tag mapping (PLC register addresses mapped to human-readable names current_speed, target_temperature, parts_count), data buffering (store locally during WAN outage, forward on reconnect no data loss), Ignition SCADA with Kepware OPC-UA server (industrial gateway bridging proprietary protocols to OPC-UA and MQTT Sparkplug B).
OEE Monitoring
Overall Equipment Effectiveness: Availability (actual run time / planned production time), Performance (actual output / rated speed output), Quality (good parts / total parts) OEE = Availability × Performance × Quality. World-class OEE is 85%+; global average is 65%. Downtime categorisation (touchscreen HMI operators tag reasons unplanned breakdown, planned maintenance, changeover, material shortage Pareto chart of loss causes), shift reports (automated PDF/email summary production count, OEE by machine, downtime events, target vs actual), ML production optimisation (correlate process parameters with quality outcomes, identify optimal settings).
SCADA Integration
Connect SCADA systems to cloud analytics: Ignition to AWS IoT (MQTT Sparkplug B real-time tag values from factory floor to cloud), historian integration (OSIsoft PI, Wonderware read historical process data for ML model training), alarm management (SCADA alarm data centralised frequency analysis, flooding detection, operator response time), IT/OT data bridge (join SCADA time series with ERP production orders and materials enable analytics spanning the IT/OT boundary).
Edge Computing
Process data at the factory floor: AWS IoT Greengrass (Lambda functions and ML models on industrial gateways local rules, offline operation, reduced cloud bandwidth), NVIDIA Jetson (edge ML inference for computer vision quality inspection classify defects in <100ms, no cloud round-trip), data aggregation (compute OEE, statistical summaries, anomaly scores at edge send only derived metrics to cloud, not raw time series).
OT Network Security
ICS/OT cybersecurity per ISA/IEC 62443: network segmentation (Purdue Model OT network separated from IT and internet via firewall and DMZ), unidirectional data flow (data diode from OT to IT prevents cyberattacks from reaching control systems), asset inventory (complete, current inventory of all OT assets PLC models, firmware versions, protocols), OT anomaly detection (Claroty, Dragos, or Nozomi Networks passive OT network monitoring, detect unusual communication patterns without active scanning that could disrupt industrial equipment).
Why Companies Choose ClickMasters
Vendor-neutral secure protocol Siemens, Allen-Bradley, Beckhoff, Fanuc, Mitsubishi
Basic: Vendor-specific only
MQTT payload format for industrial data Ignition SCADA to AWS IoT Core
Basic: No standardised payload
65% global average quantified improvement target
Basic: "OEE monitoring" (no benchmark)
Industrial gateway bridging proprietary protocols to OPC-UA and Sparkplug B
Basic: "OPC-UA gateway" (no specifics)
OT network segmentation standard data diodes, unidirectional flow for security
Basic: Basic firewalls only
Our Industrial IoT Process
A proven methodology that transforms your vision into reality
IIoT Discovery
Machine inventory (PLC models, protocols, firmware versions), connectivity audit (available Ethernet ports, existing networks), OEE targets, OT security review (current segmentation, patch status). Deliverable: IIoT Assessment + Roadmap.
OPC-UA / Modbus Connectivity
OPC-UA client configuration, Modbus TCP/RTU wiring, tag mapping (PLC address → human-readable name), data buffering (local storage for WAN outage), Kepware/Ignition gateway setup. Deliverable: Machine Data Available in MQTT.
OEE Monitoring System
Availability (planned vs actual run time), Performance (actual vs rated speed), Quality (good vs total parts), downtime categorisation (HMI touchscreen for operators), Pareto charts, shift reports (automated PDF/email). Deliverable: OEE Dashboard + Reports.
SCADA Integration
Ignition Sparkplug B to AWS IoT Core, historian integration (OSIsoft PI/Wonderware), alarm centralisation, IT/OT data bridge (join SCADA time series with ERP). Deliverable: SCADA Cloud Integration.
Edge Computing & Security
Greengrass on industrial gateway (local rules, offline operation), Jetson for vision inspection, OT network segmentation (Purdue Model), unidirectional data flow, Claroty/Nozomi anomaly detection. Deliverable: Edge Computing + OT Security.
Technology Stack
Modern tools we use to build scalable, secure applications.
Back-end Languages
Front-end Technologies
Databases
Cloud & DevOps
Industry-Specific Expertise
Deep expertise across various sectors with tailored solutions
OEE Improvement Project
Predictive Quality
Legacy PLC Connectivity
Edge Vision Inspection
Industrial IoT Development Pricing
Transparent pricing tailored to your business needs
IIoT Discovery
Perfect for businesses that need iiot discovery solutions
Package Includes:
- Timeline: 1 - 2 weeks
- Best For: Machine inventory, protocol audit, connectivity plan, OT security review
- Dedicated Project Manager
- Quality Assurance Testing
- Documentation & Training
OPC-UA / Modbus Connectivity
Perfect for businesses that need opc-ua / modbus connectivity solutions
Package Includes:
- Timeline: 2 - 4 weeks
- Best For: PLC tags, data buffering, cloud routing, Kepware/Ignition gateway
- Dedicated Project Manager
- Quality Assurance Testing
- Documentation & Training
OEE Monitoring System
Perfect for businesses that need oee monitoring system solutions
Package Includes:
- Timeline: 3 - 6 weeks
- Best For: Availability + performance + quality, downtime tags, shift reports
- Dedicated Project Manager
- Quality Assurance Testing
- Documentation & Training
SCADA Integration
Perfect for businesses that need scada integration solutions
Package Includes:
- Timeline: 3 - 6 weeks
- Best For: Ignition Sparkplug B, historian, alarm management, IT/OT bridge
- Dedicated Project Manager
- Quality Assurance Testing
- Documentation & Training
Edge Computing
Perfect for businesses that need edge computing solutions
Package Includes:
- Timeline: 3 - 6 weeks
- Best For: Greengrass or Jetson, local ML, aggregation, offline operation
- Dedicated Project Manager
- Quality Assurance Testing
- Documentation & Training
OT Network Security
Perfect for businesses that need ot network security solutions
Package Includes:
- Timeline: 2 - 4 weeks
- Best For: Segmentation, data diode, asset inventory, Claroty/Nozomi monitoring
- Dedicated Project Manager
- Quality Assurance Testing
- Documentation & Training
Full IIoT Platform
Perfect for businesses that need full iiot platform solutions
Package Includes:
- Timeline: 6 - 12 weeks
- Best For: Connectivity + OEE + SCADA + edge + security + analytics dashboard
- Dedicated Project Manager
- Quality Assurance Testing
- Documentation & Training
* All prices are estimates and may vary based on specific requirements. Contact us for a detailed quote.
CEO Vision
To build scalable, intelligent custom software development solutions that empower businesses to grow, automate, and transform in a digital-first world.
We are not building software. We are architecting the infrastructure of tomorrow — systems that think, adapt, and grow alongside the businesses they power. Our mission is to make cutting-edge technology accessible to every ambitious team on the planet.
Amjad Khan
CEO
12+
Years
300+
Projects
98%
Retention
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