Custom Software Development for Manufacturing Operations
Solutions for Pharma, Cosmetics, Food and other Manufacturing Industries
Your production processes are unique. Why shouldn't your software be? We develop tailored software, precisely matched to your requirements. Maximum control over your data, full industry-specific compliance, and software that grows with your business.
What is Custom Software Development?
Custom Software Development refers to creating software solutions specifically designed for your company's unique requirements. Unlike standard software, custom software is precisely tailored to your processes, compliance requirements and business objectives.
In manufacturing, this means: Your production planning, resource management, quality control, and regulatory requirements are aligned with your processes and built into the software. The software adapts to your processes, not the other way around.
At onsector, we use web-based On-Premise solutions. This gives you complete control over your data, meets the highest security standards and allows every employee an easy access to the software.
Why Custom Software for Manufacturing?
6 decisive reasons for tailored software solutions
Compliance & Regulatory Requirements
The pharma, food, and cosmetics industries are subject to complex regulations like 21 CFR Part 11, HACCP, GMP, and GDPR. Standard software usually only offers generic compliance modules. Custom software is developed with these requirements from the start. Our solutions include integrated audit trails, electronic signatures, and GxP-compliant functions, not as an afterthought, but as a fundamental part of the architecture.
Complex Production Processes
Manufacturing in pharma, cosmetics, and food has characteristics that standard software cannot map: Multi-line production with different cycle times, batch tracking across multiple production stages, cleaning validation between batches and complex resource optimization. Custom software is precisely tailored to your production process, so valuable time and resources can be saved.
Integration with Legacy Systems
Many manufacturing companies work with 10-20 year old ERP systems, proprietary MES solutions or different databases per department. Standard software often integrates poorly with legacy systems. Custom software is built with APIs and interfaces to seamlessly connect your existing systems.
ROI & Cost Savings
Custom software has a higher ROI compared to standard software solutions. The initial integration costs are higher, but the long-term cost advantages are significant. You can expect substantial cost savings at the operational level through reduced overtime, minimized downtime and improved efficiency. The initial investment typically pays back within 12-18 months.
Competitive Advantage
Standard software functions are identical across all competitors. With custom software, you create unique process optimizations that only you have. Your proprietary planning algorithm that optimally plans your specific production, your unique quality assurance integration, or your specialized formula management system are competitive advantages anchored in the software.
Scalability & Future-Proofing
While standard software requires new licenses for each additional user or new module, custom software is designed from the start for your growth. When you grow from a factory with 50 users to a factory with 200 users, the software scales without additional license costs. We developed our software modularly with state of the art technologies, so the software remains maintainable and expandable even multiple years from now.
Standard Software vs. Custom Software
The decisive difference for manufacturing companies
| Criterion | Standard ERP/MES/Workflow | Custom Software |
|---|---|---|
| Customization | Limited configuration | Unlimited customization |
| Implementation time | 2-12 months | 4-18 months |
| Process adaptation | You adapt to the software | Software adapts to you |
| License costs | Recurring fees per user | One-time or variable |
| Data control | Often cloud-based | On-Premise or cloud-based |
| Integration | Predefined interfaces | Custom APIs |
| Compliance | Generic functions | Industry-specific |
| Scalability | License-dependent | Unlimited |
Customization
Implementation time
Process adaptation
License costs
Data control
Integration
Compliance
Scalability
Custom software provides the flexibility and control manufacturing companies need to optimally digitize their unique processes.
Custom Software for Your Industry
Every manufacturing industry has unique characteristics. We develop for your specific sector.
Pharmaceutical Industry
Pharmaceutical manufacturers face the strictest regulatory requirements. Our custom software is developed GMP and FDA compliant from the ground up.
Challenges
- Longest regulatory cycles (FDA/EMA approvals)
- Batch-specific documentation requirements
- Audit trails required for every action
- 21 CFR Part 11 compliance (electronic signatures)
Custom Software Features
- Batch tracking with unique batch ID
- Electronic signatures (21 CFR Part 11 compliant)
- Deviation tracking and change control
- Automatic audit trail generation
- Stability data management
Cosmetics & Personal Care
The cosmetics industry is characterized by high product variety and fast market cycles. Custom software must be able to handle this dynamic.
Challenges
- Hundreds product variants
- Complex formulas and ingredient combinations
- Variable packaging sizes and labels
- Short time-to-market requirements
Custom Software Features
- Formula management with versioning
- Supply chain optimization (raw material availability)
- Format change management
- Complex production dependencies
- Fast prototyping support
Food & Beverage
Food safety is paramount. Custom software must seamlessly integrate HACCP processes and support allergen management.
Challenges
- Highest food safety standards (HACCP)
- Seasonal raw material availability
- Short shelf life and freshness concerns
- Allergen management and cross-contamination prevention
Custom Software Features
- HACCP integration with critical control points
- Allergen tracking and declaration
- Cleaning scheduling
- Temperature & humidity logging
- FIFO expiration date management
General Manufacturing & Heavy Industry
Manufacturing operations with long cycles and complex supply chains benefit from custom software that maps their specific requirements.
Challenges
- Long production cycles (days to weeks)
- Equipment maintenance critical for production
- Individual customer orders (made-to-order)
- Complex supply chain dependencies
Custom Software Features
- Preventive maintenance
- Order-to-cash tracking
- Equipment downtime logging
- Customized BOM (bill of materials) per order
- Real-time production floor visualization
The onsector Custom Software Development Process
Structured, transparent and with clear milestones
Phase 1: Requirements Analysis
Deep understanding of your requirements through meetings and/or workshops with all stakeholders (production, quality, planning, IT). We document your current processes, identify pain points and optimization potential, and define measurable success criteria and KPIs. The result is a comprehensive requirements document with functional and non-functional requirements, regulatory specifications, and integration requirements.
Phase 2: Architecture & Design
Based on requirements, we design the software architecture. We create system architecture with modular, service-oriented design, decide on on-premise deployment strategy, plan database design, and define APIs for integrations. In parallel, we develop the UI/UX prototypes for faster feedback. At the end the tech stack is defined, which is optimally aligned to the requirements.
Phase 3: Development & Implementation
Iterative development following Agile methodology with 3-week sprints. Each sprint begins with the sprint planning, daily standups for coordination, code development and continuous integration in the test environment. At the end of each sprint: sprint review (demo to you) and sprint retrospective. Parallel automated tests run: unit tests, integration tests, security scans and performance tests. Every three weeks you receive working software updates and can provide feedback.
Phase 4: Quality Assurance & Testing
Comprehensive QA before go-live: Functional testing (every requirement tested against software), user acceptance testing with your users, and regression testing (old functions still work). Non-functional testing includes performance tests (does software run fast enough with 1,000 users?), security testing and vulnerability scans, compliance validation and usability testing. We simulate production environments with real data and actual load scenarios.
Phase 5: Deployment & Launch
Secure deployment in your on-premise infrastructure. Pre-launch: Environment setup on your servers, user training in 2-3 sessions for different user groups, documentation (admin manual, user manual, API docs). Launch day: Phased rollout, real-time monitoring and support from our team. Post-launch: Go/no-go review and user feedback collection.
Phase 6: Maintenance, Support & Optimization
After launch begins the long-term partnership. Operational support: incident management (bugs prioritized), performance optimization and user support plus training. Maintenance: Security patches as soon as available, dependency updates (libraries and frameworks stay current) and database optimization during growth. Continuous improvement: Regular KPI reviews, feature request prioritization, A/B testing of UI/UX improvements and performance benchmarking.
Are you ready to transform your production processes?
Schedule a free consultation and discover how custom software development can optimize your production processes.