ElectronIxTrace

ElectronIx Trace · product traceability

Know exactly which units are affected. Then prove it.

ElectronIx Trace records what went into every unit you build, what was done to it, who did it and what it measured. Scan the code on the product and the whole history comes back — in seconds, on your own hardware, with or without a network.

On-premise. Works with no internet. Quoted per plant, not per seat.

01

What it costs when the record is not there

Four situations that arrive without warning. In each one the difference between a bad day and a bad quarter is whether you can answer at the level of a single unit.

The OEM asks for March

Your customer's quality team wants torque records for a part number you shipped in March. You have a shift log and a stamped inspection sheet. Neither is per unit.

A unit comes back failed

One returned unit, one serial number. Which bearing lot was in it, what did it measure at end of line, and who built it? The answer decides whether this is one unit or a batch.

A supplier lot is bad

Your supplier calls about a gasket lot. You built four hundred units that week. Without per-unit consumption records, all four hundred are contained, including the ones that never touched the lot.

A warranty claim with no build record

Eighteen months on, a claim arrives. You cannot show what the unit measured when it left, so you cannot argue it left in spec. The claim is settled on their terms.

02

From job card to a scan that returns everything

Six stages. Each one adds to the record, and the record is what you get back when someone scans the product.

  1. 10

    Job card issued

    A job card names the product, the revision and the quantity.

    The unit is born against the job card and gets its identity — a 26-character code that sorts by time and is never reused, even if the unit is later scrapped.

    Captured here

    • Job card number
    • Product and revision
    • Quantity and due date
  2. 20

    Components issued against the BOM

    Sub-components are drawn from store and scanned against the bill of materials.

    A component that is not on the BOM for that revision is refused, not warned about. A wrong part at this station is a hard stop.

    Captured here

    • Component lot codes
    • Serialised sub-assembly identities
    • BOM line satisfied
    • Operator
  3. 30

    Assembly stations capture process data

    Each operation captures what it is configured to capture.

    Values are checked against the limits configured for that point at that moment. A value outside the window blocks the unit and routes it down the failure path the operation defines.

    Captured here

    • Torque per fastener
    • Grease applied
    • Instrument that read it
    • Both timestamps
  4. 40

    Test, sub-assembly and final

    Tests record their readings, not just a verdict.

    The test gate holds the unit until the named test passes. A pass with no readings behind it is a stamp, and a stamp is not evidence.

    Captured here

    • Test name and verdict
    • Underlying readings
    • Raw device payload
    • Station and operator
  5. 50

    Mark and label

    Identity is applied to the part and read back.

    Your own label template, loaded as-is and versioned with an effective date. A direct part mark for parts that go through wash, paint or heat. Both from one binding, so the part and the record cannot disagree.

    Captured here

    • Template version used
    • Read-back and grade
    • Reprints with reason and authoriser
  6. 60

    Scan anywhere, get everything

    The code on the product returns that unit's complete history.

    The page works on a phone, on the plant LAN, with no internet. It is a self-contained document with nothing loaded from outside, because the first shop floor it ran on had no route to the internet.

    Captured here

    • Full genealogy tree
    • Every measurement with its limits
    • Event history with hash chain

Read the longer version in how ElectronIx Trace works.

03

A sample unit, with its real record

This is the record, not a picture of one. Search a serial, filter the captured values, open a reading to see the exact bytes the instrument returned, and download the whole history.

A real scanner types the code and presses enter, which is exactly this field.

Sample units

EX-VLV-2200

SHIPPEDrev A
Serial
VLV-2608-1001
Unit id
468CVDC1ZJ79TSGR8HD1BYBB2P
Job card
JC-2608-0071
Built
18 Aug 2026
Dispatched
18 Aug 2026
Customer
Southern Pumps, Coimbatore

Captured values

Captured process values for unit VLV-2608-1001
PointValueLimitsVerdictSourceWhenDetail
Final torque12.3 Nm10 – 14 NmPASSDEVICE18 Aug 2026, 06:23
Grease appliedYesPASSMANUAL18 Aug 2026, 06:26
Hydro test pressure14.6 bar13.5 – 16 barPASSDEVICE18 Aug 2026, 06:31
Leak rate1.52 ml/min≤ 3 ml/minPASSDEVICE18 Aug 2026, 06:33

Components consumed

Components consumed by unit VLV-2608-1001
ItemDepthKindQtyOp
Gasket, body, NBR · GSK-2608-A141LOT1 ea20
Seal, stem, PTFE · SEAL-2607-B221LOT2 ea20
Bearing, 6204-2RS · BRG-2608-C071LOT2 ea20
Body casting, CF8M · CAST-2606-D311LOT1 ea20
Screw, M6 x 20 · SCR-M6-201LOT4 ea30
Stem sub-assembly · SA-41002SERIAL1 ea20

Event history

Event history for unit VLV-2608-1001
EventWhenOpStationOperatorChain hash
BORNJob card JC-2608-007118 Aug 2026, 06:15168b7ee04428efef
MARK_APPLIEDLabel printed, read back grade B18 Aug 2026, 06:1710ST-01R. Kumarf2a3600775873f40
OP_COMPLETEComponents verified against BOM18 Aug 2026, 06:2120ST-01R. Kumarb258f41bd98349af
OP_COMPLETETorque captured from TW-0118 Aug 2026, 06:2430ST-01R. Kumareb8c2da39a19dd75
OP_COMPLETEGrease confirmed, cover fitted18 Aug 2026, 06:2740ST-01R. Kumar0b0068800d41bba0
OP_COMPLETEEOL test passed18 Aug 2026, 06:3550ST-01R. Kumar0936f8bacf413332
SHIPPEDSouthern Pumps, Coimbatore18 Aug 2026, 10:1567e13a569b0b37e6

Every row is append-only and chained to the one before it. Changing a historical value breaks every hash after it.

Sample dataset: 24 units across 3 job cards and several component lots, built on the route the product ships as its worked example.

04

A supplier calls about a lot. How wide is the problem?

This is the query the whole system exists to answer. Give it a lot code and it returns the units that consumed it, the customers they went to, the containment window — and how many units are provably clean.

Lots in the sample dataset

Enter a lot code to see which units consumed it, who they shipped to, and the containment window.

Running against the sample dataset above. On your plant it runs against your units, as an indexed lookup rather than an overnight report.

05

Your data, the way you need to see it

The screens a plant actually uses: find a unit, see what is blocking the line, watch a parameter drift before it fails, and manage the templates and stations behind it.

Unit search

Scan or search

VLV-2608-1004
Model
EX-VLV-2200
Revision
A
Job card
JC-2608-0071
State
SHIPPED

Captured values

  • Final torque12.6 NmPASS
  • Grease appliedYesPASS
  • Hydro test pressure15.3 barPASS
  • Leak rate1.24 ml/minPASS

Interface renderings of the ElectronIx Trace screens, drawn to the station design constraints: large hit targets, no hover states and no right-click, because a gloved hand on a touchscreen has neither.

06

What changes, depending on where you sit

Quality head

  • Answer an OEM audit from the record instead of from memory.
  • Bound a containment in minutes, and prove which units are clean.

Production head

  • See which operation is blocking units and why, by gate.
  • Change a torque window or a sampling rule without waiting for a software release.

Plant head

  • A network failure costs you nothing: stations keep capturing and catch up later.
  • Start on one line and widen when it has earned it.

Owner

  • Meet the traceability clause in a customer contract without an enterprise MES budget.
  • Your production data stays on your hardware, in your plant.

Maintenance and IT

  • One service, one PostgreSQL database, no cloud dependency in the runtime path.
  • Updates verify before downloading, apply atomically and roll themselves back if unhealthy.

None of these quite you?

Describe your line and we will tell you what Trace would capture at each station, and what it would not.

08

What it connects to

Specificity is the proof here, so this list is deliberately concrete. If something you run is not on it, ask — the answer will be a yes or a no, not a maybe.

Machine and instrument data

  • RS232 and RS485 serial, including multidrop instrument segments
  • Ethernet, TCP line protocols and Modbus TCP
  • PLC and HMI capture, with an interlock released back to the fixture
  • Manual stations capturing the same points against the same limits

Marking and identity

  • Zebra printers driven as raw ZPL II over TCP 9100 — no OS print driver
  • USB and file sinks for sites with no network printer
  • Laser direct part marking with Data Matrix and mark read-back
  • Handheld and fixed imagers; DPM-capable imagers where parts are directly marked

Platform

  • PostgreSQL 16 on an edge box you own, one per plant
  • Debian 12 or Ubuntu 22.04+ on the edge; Windows or Linux on stations
  • Signed over-the-air updates, with an identical offline USB path
  • Multi-plant ready: tenant isolation is in the schema from the first migration

09

Where we fit, and where we do not

Every vendor comparison is written by the vendor. Here is ours, with the places we lose stated first.

ElectronIx Trace compared with enterprise MES suites and local AIDC integrators
 Enterprise MES suiteLocal AIDC integratorElectronIx Trace
Certification and validationValidated deployments in regulated industriesSome hold ISO certification as a businessNone. We are built to produce audit evidence, not certified
ERP connectorsDeep, supported SAP and Oracle integrationOften have a connector to the ERP you runNone built. A documented seam, which is not the same thing
Support organisationGlobal, tiered, 24/7 availableLocal, on site within daysOne engineer, in one time zone
Works with the network downUsually assumes uptimeUsually stops capturingDurable local spool first, network second
If billing lapsesVaries, rarely statedProject is bought outrightProduction capture continues. There is no state that stops it
Process values per unitYes, with configuration effortUsually scan events onlyTorque, grease, readings, with limits and the instrument
Recall querySupported, often a reporting jobFrequently a change requestIndexed lookup, by lot and by machine and time window
Record integrityAccess control, audit logsOrdinary editable tablesAppend-only in the database, hash chained per unit
Time to first line liveMonths to quartersBespoke build, schedule variesTwo to three weeks from walkthrough
Commercial modelPer user and per module, plus implementationProject fee, then change requestsQuoted per plant. No per-seat charge

The three rows at the top are ones we lose, and they are real. If a validated MES, deep ERP connectors or a global support organisation is what decides your purchase, buy the suite — you will not be happy with us.

Longer, per-competitor versions: versus Siemens Opcenter, versus a barcode integrator project.

10

What the first month looks like

One line first. If the record it produces is not what you wanted, you have spent three weeks, not a year.

  1. Week 0

    Walkthrough and configuration

    We walk your line, list the operations, the capture points and their limits, and collect your label template. Nothing is installed yet.

    From you: An hour on the floor, your BOM for one product, and your current label file.

  2. Week 1

    One line, dry run

    The route is configured and simulated with no hardware attached, so configuration errors surface before the line is involved. The edge box is prepared.

    From you: A decision on which line goes first, and network access to the printer.

  3. Week 2

    Live on one line

    Stations go live at the configured operations. Production downtime for the changeover is close to zero, because capture starts at the next unit rather than requiring a stop.

    From you: One shift's operators for a short handover, and someone who can authorise a rework.

  4. Week 3 onward

    Widen, once it has earned it

    Second line, then plant, then multi-plant if you have more than one site. Each step is configuration, not a new project.

    From you: A judgement call on whether the first line is actually giving you the record you wanted.

11

Who builds this

ElectronIx is an industrial automation and software business in Coimbatore, run by Dinesh Kumar G, with nine years in PLC and SCADA work — Siemens TIA Portal, Allen Bradley, Omron Sysmac — electrical design in AutoCAD Electrical and EPLAN, Fanuc CNC systems, machine vision, special purpose machines and IIoT.

Trace is written in Rust, runs on PostgreSQL, and is supported directly by the engineer who wrote it. There is no support tier, no ticket queue and no account manager relaying your question to a developer in another country. That is a genuine limitation when you want 24/7 cover, and a genuine advantage when you want a straight answer about whether your controller can be read.

The same shop that builds your panels understands why a licence check must never stop a line, why a reprint needs an authoriser, and why a dead RTC battery on a panel PC quietly corrupts a traceability record. Those decisions are in the product because they were learned on a floor, not in a spec.

Engineering facts

Backend
Rust, no unsafe code anywhere
Database
PostgreSQL 16, on your hardware
Edge minimum
4 cores · 8 GB · 128 GB SSD
Station OS
Windows 10/11 or Linux
Internet
Not required, at any point
Updates
Signed, atomic, auto rollback

12

The questions plants actually ask

Does it work without internet?

Yes, and that is a design constraint rather than a feature. A station writes every event to durable local storage before attempting anything over the network, and replays safely when the edge returns. Nothing in the runtime path waits on a remote call — not licensing, not billing, not updates. A factory LAN with no internet at all is a supported configuration.

Do we need new machines?

No. Trace reads from what you already have where it can, and captures manually where it cannot. A station with no instrument captures the same points against the same limits with the same audit fields — only the source flag differs. Plants are never uniformly instrumented, and pretending otherwise is how these projects fail.

What if our PLC is old?

Old is usually fine. Serial, Modbus, a TCP line protocol or a file drop all work, and many older controllers speak one of them. Where a controller genuinely cannot be read, that station captures manually and the record is still complete. We will tell you honestly at the walkthrough which of your machines can be read and which cannot.

Can it print our existing label?

Yes — that is the intended path. Your template is loaded as-is and versioned with an effective date, so template changes are auditable. Trace generates ZPL natively and writes it to the printer over TCP, with no print driver on the terminal, which is also what lets a printer be swapped without touching an operator station.

How long does deployment take?

One line, typically two to three weeks from walkthrough to live, with close to zero production downtime at changeover. Widening to more lines is configuration. We would rather you start on one line and judge the record it produces than commit the whole plant on a promise.

What does it cost?

Quoted per plant, not per seat. Price is driven by the number of stations, how many of them need instrument integration rather than manual capture, and whether you need direct part marking. There is no per-user cloud charge. Ask for a quote and you will get a number, not a discovery process.

Can it export to our ERP or Tally?

Not today, and we will not claim otherwise. Trace holds the job card reference your ERP already uses, so the join has somewhere to land, but there is no built ERP connector. Data is exportable and the database is yours to query. If ERP posting is essential to your decision, say so early.

What happens if the PC dies?

A station's spooled events are on its local disk; a replacement station picks up from the edge and no captured record is lost once it has been acknowledged. The edge box holds the database, so that is the machine to back up — and it is an ordinary PostgreSQL backup, on your schedule, to your storage.

Who owns the data?

You do, on your hardware, in a standard PostgreSQL database you can back up, query and export. There is no hosted service in the runtime path and no clause anywhere that makes your production record dependent on us continuing to exist.

What happens if we stop paying?

Production capture continues. A lapsed subscription restricts configuration changes and cloud sync — it does not and cannot stop capture, because halting it would destroy the record for units physically on the line, and those units then could not ship at all. There is no state in the software that stops production. Ask any other vendor to put that in writing.

Can we start with one line?

That is the recommended way in. The schema is multi-plant from the first migration, so growing later is configuration rather than a migration project, and starting small costs you nothing structurally.

Is ElectronIx Trace certified to IATF 16949 or ISO 9001?

No. Neither the software nor the company holds a certification, and any vendor telling you their software makes you compliant is selling you something. Trace is built to produce the evidence an auditor asks for — per-unit genealogy, captured values against defined limits, operator identity, and proof records have not been altered. The quality system around it stays yours.

13

Book a 20-minute line walkthrough

Twenty minutes on a call or a visit if you are near Coimbatore. We walk one line, list the operations and what each should capture, and tell you plainly which of your machines can be read and which cannot. You get that list either way, whether or not you buy anything.

We reply from Coimbatore, usually the same day. Your details are used to answer you and nothing else — see our privacy note.