From production data to managed efficiency
A vendor-independent historian and object model with built-in MES — events, shifts, KPI and material balance — layered over your existing SCADA and control systems. No lock-in, no rip-and-replace.
SCADA and control systems visualize signals and run the equipment in real time. IDC sits on top and turns those signals into answers: where the efficiency potential is, where deviations come from, how the plan is being met, and what to do. Not another screen of numbers — one window for running production.
Operational data is trapped, fragmented and late
The plant generates more data than ever — yet it is either discarded or left sitting in disconnected systems, never used to improve production efficiency.
Proprietary lock-in
Core process data trapped in closed, proprietary systems with end-of-life support and rising vendor risk.
Fragmented systems
SCADA, lab, LIMS and spreadsheets that never share one object model or one timeline.
Manual collection
Shift logs, balances and reports assembled by hand \u2014 hours late and prone to error.
No single pane
No unified window for operational decisions across units, sites and shifts.
Typical solutions — the customer's problem, and how we solve it
For each typical task on the floor: the real pain, and exactly how IDC closes it.
Production data management
An enterprise-wide real-time database — one source of truth.
- Dozens of different control systems: detail per area, but no plant-wide picture.
- Metrics are computed differently everywhere — no single source of truth.
- Control systems do not keep history — nothing to run modern analytics on.
- Consolidate data from scattered systems (control systems, LIMS, shipping, plans) into one real-time database.
- Compute all metrics by one set of algorithms — a single version of the truth.
- Long-term history as a trustworthy source of facts for incident review.
How it works
- Collectors connect to control systems (OPC UA/DA, Modbus, MQTT, IEC 61850/104) and adjacent systems (ODBC/JDBC, CSV/XML).
- Data flows to the store over a high-throughput protocol with local buffering if the link drops.
- Data is accessed via REST API; manual entry via Manual Input.
Events & shift management
Every event and handover in one window — nothing slips through.
- To react, staff watch a dozen screens — some events slip through.
- No certainty every event was handled on time and correctly.
- After handover, the incoming crew lacks the full picture of the previous shift.
- A single window for all significant events, with no system-switching.
- Fast reaction via escalation paths — route each event to the right roles.
- Execution control: who handled it, how, what was decided, what is overdue.
How it works
- Integration with sources; registration rules (from a system, from data, manual, scheduled).
- Rules for assigning owners and the context attached to each event.
- At handover the incoming shift sees the feed, the handling history and open events.
Primary production accounting
A reliable picture of what was actually done each shift.
- Plenty of process data, but no single truth on intake, throughput and output.
- Manual entry and auto-collection are not joined — gaps and accounting errors.
- No reliable primary base for reporting, balances and KPIs.
- Record what happened: start-ups, shutdowns, switchovers, regime events.
- Operational accounting of feed, output, consumables and energy.
- A single operations log tied to shifts, areas, units and time intervals.
How it works
- Joins operator manual entry with automatic field data, cutting gaps and errors.
- Turns actual events and measurements into structured production data.
- Builds the primary base for shift reporting, deviation analysis and balances.
Material & energy flow control
Balances, accounting and loss detection for material and energy.
- Unclear how much feed was really processed and where losses and imbalances arise.
- Hard to tell real losses from measurement and accounting errors.
- Energy overuse and sources of inefficiency are found too late.
- Monitor material flows and localize gaps between expected and actual.
- Bring energy use into a managed loop: control, rationing, deviation detection.
- A base for operational analysis, investigations and period close.
How it works
- Keeps a flow model tied to measurements; screens data for gross errors.
- Reconciles input and output flows per object and plant; shift/day/period balances.
- Energy metering, specific norms, plan-vs-fact, real-time monitoring and anomaly detection.
Equipment condition monitoring
The real state of equipment — service by condition, not the calendar.
- Signals exist, but the real technical condition of equipment stays opaque.
- Defects and degradation are caught late — many unplanned shutdowns.
- Maintenance by calendar or after failure, not by actual condition.
- Transparency of current state and early detection of degradation.
- Fewer failures and trips; condition-based maintenance.
- One workspace for dispatcher, reliability, thermal and safety engineers.
How it works
- In one view: what runs, what is on standby or in repair, nodes in warning/alarm.
- Pre-processed indicators (efficiency, reduced parameters, trends), not raw signals.
- Early warning of dangerous states: surge, rising vibration, overheating, axial shift.
End-to-end production KPIs
Efficiency in view at every level — where it drops, and why.
- Lots of data, but no single live picture of production efficiency.
- Deviations from targets and plan surface too late.
- The headline metric dropped — but the cause is not clear.
- One KPI system — the same data and methods at every level.
- Decompose a deviation down to its source: level, unit, asset, factor.
- Linking the shop floor to management — a basis for decisions.
How it works
- KPIs are computed from unit to business level on RTDB and accounting data.
- A deviation is seen the moment it appears, not at month-end.
- On a worsening trend — factor breakdown and routing to owners via events.
Process optimization with digital models
Digital models wired into day-to-day operations — and into action.
- Digital models exist but are not wired into day-to-day operations.
- No reliable real-time data preparation for online model runs.
- Model outputs do not turn into concrete actions and assignments.
- Real-time gathering and prep of input data, online computation of derived values.
- Integrate individual models into one production model and orchestrate them.
- Trigger runs by criteria and turn results into action.
How it works
- RTDB and Data Interface prepare data; Model orchestrates the individual models.
- Analytics triggers runs by criteria (new data, schedule, a neighbouring model request).
- Events turns conclusions into an event, an assignment and execution control.
Real screens from a working system
Not mockups — these are live IDC screens from an industrial deployment.
One modular platform over your existing automation stack
IDC doesn\u2019t replace your SCADA or controllers. It sits above them \u2014 collecting, historizing and modelling every signal into one object model, then layering MES on top. Built on open standards, deployed on-premise, extended module by module.
Modular by design
IDC is a set of components — assemble exactly the solution your plant needs and pay only for the modules you use.
Fits your existing systems
A fully documented OpenAPI. New modules need no rip-out of existing systems — they fit into your landscape and data flows.
Real-time, every protocol
All common control-system protocols plus the leading historian protocols (AVEVA PI System, Honeywell PHD) for integration and migration — and adapters for any documented protocol.
High-performance streaming calculations
Real-time derived tags, balances and KPIs are precomputed continuously, so engineers see deviations immediately instead of waiting for reports.
Built-in builders, no code
Built-in builders for mnemonic schemes, dashboards and screens — skilled users configure views and analysis without coding.
Standards-based calculation library
A built-in library of production calculations — volume/mass conversions, flows, energy and petroleum maths — to industry standards (ГОСТ 8.587/8.615/30319, API MPMS, GERG-2008/AGA-8), plus a configurable formula engine for everything else.
One pipeline — from field signal to boardroom
The same modules connect into one flow on the shared object model.
Collect & historize
Signals from АСУ ТП, SCADA, DCS and PLC stream into the real-time database.
Contextualize
The object model binds every signal to a real production asset.
Compute & detect
Analytics, KPIs, events and condition monitoring turn data into signals you act on.
Account & balance
Shifts, balances and production accounting produce trustworthy operational records.
Deliver
Reports surface the picture for every level — operator to management.
Studio configures it all without code · Manual input fills what isn't automated.
Why industrial teams choose IDC for fast, open deployments
IDC is designed for cases where a plant needs a practical data and MES layer quickly: on-premise, open, phased, and without replacing existing automation.
Value in stages, not years
A measurable result already in the first phase — not promises years away.
One platform, not five
Historian, visualization, events, shifts, reports and balances — no integration tax.
Open standards, no lock-in
OPC UA, Modbus, REST, Kafka, ClickHouse, PostgreSQL — your data stays portable.
On-premise from day one
Data stays with you — sovereignty and security, no cloud dependency.
Transparent licensing without per-tag surprises
Licensing designed to avoid per-tag lock-in — predictable as you scale.
A proven, ready-made vertical
Digital compressor station — a ready-made solution running on a real site, not generic MES.
Modules across every layer — one shared model
Each module works on the shared model and serves many solutions. Open a card to see what it's for and what it gives.
Data Interface
Every field source on one collector — any protocol.
Real-time database (RTDB)
Years of process history, served at query speed.
Object model
Tags become the plant — assets, units and lines.
Studio
Set up the platform and build screens — without code.
Maps & 3D models
See assets in space — maps and live 3D.
Manual input
Capture what doesn't arrive automatically — under control.
Analytics & calculations
Calculations, forecasts and scenarios in real time.
KPI
Efficiency KPIs across the whole hierarchy.
Events
Every event in one window — routed and resolved.
Shift
Duty and crew planning, handover, logbooks and reports on one regime.
Reports
Scheduled reporting for every level of management.
Production accounting
Events and measurements become trusted production data.
Equipment condition monitoring
Equipment health, caught before the breakdown.
Volume recalculation
Raw measurements → comparable accounting values.
Material balance
Reconcile mass flows and find the losses.
Energy balance
Account for energy and raise efficiency.
IDC.AI advisor
The data layer turned into proactive intelligence.
AI advisor for production events
When a production event fires, the advisor gives the operator a grounded recommendation — what happened, the probable cause, what to do and whom to assign. Fully on-premise: industrial data never leaves your perimeter.
Grounded, not guesswork
Answers are tied to real data, your regulations and similar past cases — with source citations. Out of context it refuses honestly instead of inventing text.
Honest confidence
The system measures how well an answer is grounded in its sources and shows a confidence level — high, medium or low.
The human decides
The advisor suggests but never acts on equipment autonomously. The decision and the responsibility stay with the specialist.
From hint to action
A recommendation turns into an assignment in one click. Operator thumbs-up / thumbs-down ratings keep improving quality.
On-premise
A local language model on your own hardware. No external clouds or APIs — data stays inside the perimeter.
Shadow mode
Quality is validated on the live event stream before going live — with no risk to the operator.
Configurable for your plant
The advisor is not a universal out-of-the-box black box — it is an adaptable tool. A configurator tailors it to a specific site:
Domain expertise is embedded by the customer and the integrator — for the equipment, process and regulations of a specific plant, compressor station or processing facility.
What's ready, and what's in development
- Data collection
- RTDB / historian
- Object model
- Tags
- Trends
- Events & shifts
- Dashboards & mnemonics
- Material balance
- KPIs & reports
- Roles & ACL
- Calculation library (to standards)
- AI advisor
- Automatic recommendations
- Regulations knowledge base
- Similar-event analysis
Built for heavy industry
Oil & Gas
Upstream & midstream
Refining & petrochemicals
Refineries & chemical complexes
Gas processing & transport
GPP, compressor stations, pipelines
Metallurgy
Ferrous & non-ferrous, steelmaking
Mining & ore processing
Extraction & beneficiation
Power & energy
Generation & heat networks
Chemicals & fertilizers
Large-tonnage chemistry
Cement & building materials
Clinker & grinding
Who benefits
Chief engineer
Transparency of deviations, events and balances.
Production manager
Shifts, KPIs, plan fulfilment.
Control systems / IT
Unified collection, historian, API, access control, on-premise.
Process engineer
Trends, root causes, calculations, reports.
Management
Indicators, losses, efficiency, transparency.
What this means for the business
Outcomes, stated plainly \u2014 the operational gains a single, open data layer unlocks.
One model, not a zoo
A single data model replaces a patchwork of disconnected systems.
Faster decisions
Investigations and operational calls made in minutes, not shifts.
Flow transparency
Material and energy flows made visible across every unit.
Independence
No vendor lock-in \u2014 your data, your standards, your terms.
What IDC does not replace
IDC does not replace SCADA and does not control equipment directly. It runs above your existing automation layer and turns process signals into history, an object model, events, KPIs, reports and production decisions.
Start with a focused pilot
- Connect 1–2 data sources
- Onboard 500–5000 tags
- Build the area object model
- Set up 2–3 screens
- Add events, reports, balance
- Show engineers and management
- A demo loop on your data
- List of integrations
- Rollout scale estimate
- Industrial deployment plan
Deployed on your servers
IDC is developed by an engineering team focused on industrial data platforms — RTDB, MES, production accounting and heavy-industry digitalization. Deployment references are available on request, under NDA where applicable.
Request a technical demo on your architecture
Send us your current stack — SCADA/DCS, PLC protocols, historian, number of tags and the production task you want to solve. We will show which IDC modules fit and what a focused pilot would look like.