Predictive Maintenance
Wear and irregular patterns get flagged before they cause a breakdown.
One system that schedules your floor, predicts machine failures before they happen, and shows you a live digital twin of every line — built for people who run production, not just report on it.
Live Digital Twin — actual Nexora interface, not a mockup
Scheduling, maintenance, machine tracking and your existing ERP — connected instead of scattered across spreadsheets.
Wear and irregular patterns get flagged before they cause a breakdown.
Jobs grouped by tooling and material so changeovers get shorter.
Real-time status and OEE for every machine, not last week's report.
The right supervisor gets notified immediately, not at the next meeting.
Connects to the ERP and stock systems you already run.
Ask "why was line 3 behind today?" and get a straight answer.
The whole floor distilled into one 0–100 score, so you see at a glance when something is slipping.
On-time, utilization and delays compared week over week — exported to Excel or PDF in one click.
Jobs with stretched setups or at-risk due dates surface in a live warning band, before the problem grows.
No mockups or static rules. Nexora runs real-time machine learning models directly on your server to constantly optimize your production.
Predicts job delays using a local TensorFlow.js MLP model that learns from actual completion times. Replaces rule-of-thumb heuristics.
Analyzes live vibration, temperature, and spindle load using ISO 10816 standards, combined with operator logs, to forecast machine failures.
Uses an EMA feedback loop to measure actual transition times between parts, automatically updates the similarity matrix, and reduces setup times by 35%+.
A 100% local, air-gapped custom LLM developed by our team that uses tools to analyze and explain factory health and risks in plain language. Your data never leaves the factory.
Six specialized agents watch your floor around the clock. These are real screens from the Nexora app — not mockups.
Drag, drop and resize jobs on a live Gantt board. The engine cuts setup time by 35%+ by sequencing similar jobs together, and re-plans in under 30 seconds when a breakdown or rush order hits.
Tracks utilization on every machine in real time and shows exactly which one is holding up the line — and what today's idle time is actually costing you.
Flags high-risk material transitions between jobs before they happen, and suggests the buffer step that keeps scrap — and cost — down.
Scores failure risk per machine from live sensor data, and slots a short maintenance window into an existing setup gap — instead of stopping the line later.
A second-by-second view of every line and machine — running, idle, in maintenance or down — laid out the way your floor is actually laid out.
The screen your operators actually use: active job, progress, what's next, and a one-tap way to start calibration — no training manual required.
The full product story in one polished PDF — use cases, the AI engine flow, measurable gains and technical specs. Perfect for forwarding to your production or finance manager.
Free download — instant access to your PDF copy.
Import from Excel or enter orders in the Planning Module. Before it builds a single slot, the engine counts backward from each due date to flag what won't make it in time — while there's still time to react.
The engine sequences jobs in three passes — emergency jobs (under 4 hours to due) first, then same-part runs that cut setup time in half, then everything else by earliest due date. Fixed break times and maintenance windows are factored in from the start.
The plan gets one last drag-and-drop pass on the Gantt board. Once approved, each machine gets its queue and each operator gets a Start / Pause / Complete terminal screen.
When load between same-type machines drifts past 120 minutes, the system suggests a rebalance — you approve it, nothing moves on its own. Actual shop-floor data feeds back into OEE and the delay/breakdown predictions.
Nexora sits between your machines and your ERP — it adds a layer, it doesn't replace one.
Your shop floor data is sensitive. Nexora is built to treat it that way by default.
Every request runs through an Nginx SSL reverse proxy, and sessions are authenticated with JWT tokens — no plaintext traffic, no shared passwords.
EU-based cloud hosting or a fully on-premise deployment for sensitive environments.
Operators, supervisors and admins each see exactly what their role needs — nothing more.
Your production data is yours. Export it or delete it whenever you choose.
We understand that software changes can be disruptive. That is why NexoraProd is engineered for zero-risk adoption.
Keep your recipes, schedules, and capacity logs completely within your local network (air-gapped). Your data never leaves your factory.
We connect newer smart machines as well as older manual stations using affordable industrial IoT sensor bridges and tablets.
Designed specifically for operators on the floor. Giant touch buttons, simple colors, and translation options so anyone can use it.
NexoraProd runs parallel to your existing spreadsheets during the pilot. We only switch over once you are completely confident.
Enter your own numbers — the math runs on your data, not a brochure case study.
Based on the engine's 35% setup-time reduction. Your actual results depend on your job mix — that's exactly what the early access pilot measures.
Test It With Your DataDefine a few machines, set their cycle times, and see a live schedule of an 8-part job flowing through your line. Then flip Nexora on.
Representative simulation: an 8-part job on a sequential line. Nexora mode applies −15% on the bottleneck and −5% elsewhere — figures based on pilot measurements.
Managing your floor with old-school methods costs you time, efficiency, and money. See how NexoraProd compares to traditional scheduling.
| Feature / Pain Point | Traditional (Excel / Paper) | NexoraProd AI OS |
|---|---|---|
| Scheduling Speed | Traditional (Excel / Paper) Hours or days of manual work. A single rush order or machine breakdown ruins the entire plan. | NexoraProd AI OS Under 30 seconds. Automatically re-plans on any disruption or priority change. |
| Bottleneck Detection | Traditional (Excel / Paper) Discovered days later, through retrospective reports, after the delay already happened. | NexoraProd AI OS Real-time & live. Highlights line bottlenecks instantly and alerts supervisors before queues build. |
| Machine Maintenance | Traditional (Excel / Paper) Reactive. Production stops when machines fail, causing unplanned downtime and repair costs. | NexoraProd AI OS Predictive. Wear trends are flagged via sensor analysis and fixed during planned setup gaps. |
| Operator Data Input | Traditional (Excel / Paper) Manual paper logs at shift end. Prone to typos, missing data, and delays. | NexoraProd AI OS Single-tap touch terminal on floor. Automatically feeds OEE and job progress. |
| Transition Waste | Traditional (Excel / Paper) Depends on scheduler or operator experience. Bad sequencing results in high scrap rate. | NexoraProd AI OS AI transition optimizer sequences similar tooling/materials, cutting scrap and setup times. |
Join now and keep this rate when Nexora officially launches. No surprises later.
For a single line or pilot shop
For shops ready to scale up
Multi-plant operations
A typical setup goes from kick-off to your first live dashboard in about 5–10 business days, depending on how many machines you connect.
No. Nexora sits between your machines and your ERP, and syncs with the system you already use — it adds a layer, it doesn't replace one.
Yes. Data is encrypted in transit and at rest, and enterprise customers can choose EU-based hosting or a fully on-premise deployment.
Any machine with a PLC, MTConnect or OPC-UA interface, plus manual stations via tablet — we're building compatibility with common brands like Mazak, DMG, Haas, Trumpf and Amada.
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Nexora is a product of Ulusoy Digital — engineered, deployed and supported by a real team. Built to clear the checklist your IT, finance and legal departments actually care about.
Learn how to overcome blue-collar resistance, ensure data security, integrate legacy machinery, and use AI to increase OEE by 35%. Download the complete PDF guide instantly.