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.
- 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
- 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
- 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
- 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
- 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
- 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
| Point | Value | Limits | Verdict | Source | When | Detail |
|---|---|---|---|---|---|---|
| Final torque | 12.3 Nm | 10 – 14 Nm | PASS | DEVICE | 18 Aug 2026, 06:23 | |
| Grease applied | Yes | — | PASS | MANUAL | 18 Aug 2026, 06:26 | |
| Hydro test pressure | 14.6 bar | 13.5 – 16 bar | PASS | DEVICE | 18 Aug 2026, 06:31 | |
| Leak rate | 1.52 ml/min | ≤ 3 ml/min | PASS | DEVICE | 18 Aug 2026, 06:33 |
Components consumed
| Item | Depth | Kind | Qty | Op |
|---|---|---|---|---|
| Gasket, body, NBR · GSK-2608-A14 | 1 | LOT | 1 ea | 20 |
| Seal, stem, PTFE · SEAL-2607-B22 | 1 | LOT | 2 ea | 20 |
| Bearing, 6204-2RS · BRG-2608-C07 | 1 | LOT | 2 ea | 20 |
| Body casting, CF8M · CAST-2606-D31 | 1 | LOT | 1 ea | 20 |
| Screw, M6 x 20 · SCR-M6-20 | 1 | LOT | 4 ea | 30 |
| Stem sub-assembly · SA-4100 | 2 | SERIAL | 1 ea | 20 |
Event history
| Event | When | Op | Station | Operator | Chain hash |
|---|---|---|---|---|---|
| BORNJob card JC-2608-0071 | 18 Aug 2026, 06:15 | — | — | — | 168b7ee04428efef |
| MARK_APPLIEDLabel printed, read back grade B | 18 Aug 2026, 06:17 | 10 | ST-01 | R. Kumar | f2a3600775873f40 |
| OP_COMPLETEComponents verified against BOM | 18 Aug 2026, 06:21 | 20 | ST-01 | R. Kumar | b258f41bd98349af |
| OP_COMPLETETorque captured from TW-01 | 18 Aug 2026, 06:24 | 30 | ST-01 | R. Kumar | eb8c2da39a19dd75 |
| OP_COMPLETEGrease confirmed, cover fitted | 18 Aug 2026, 06:27 | 40 | ST-01 | R. Kumar | 0b0068800d41bba0 |
| OP_COMPLETEEOL test passed | 18 Aug 2026, 06:35 | 50 | ST-01 | R. Kumar | 0936f8bacf413332 |
| SHIPPEDSouthern Pumps, Coimbatore | 18 Aug 2026, 10:15 | — | — | — | 67e13a569b0b37e6 |
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.
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.
Scan or search
- 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.
07
Built for discrete manufacturing, configured per plant
Each of these has its own capture points, its own failure scenario and its own route shape. Pick the one closest to your product.
Auto components and Tier 1/2
Your OEM customer can ask for the build record of a single part number from eight months ago and expects it the same week. Trace keeps that record per unit, in a form that holds up when it is challenged.
Pumps and valves
A pump that leaks in the field is traced back to one gasket lot or one under-torqued flange. Trace keeps the values that tell you which, per unit.
Switchgear and electricals
Electrical assemblies fail on components you did not make. When a contactor batch turns out to be bad, the question is which panels have it inside them.
EV components
EV programmes arrive with traceability written into the contract. Cell lots, module serials and busbar torque have to be recorded per unit from the first production part.
Precision machining and export engineering
Export customers ask for material certificates, dimensional records and the machine a part was made on. The parts are often bare metal, so identity has to survive handling, wash and heat.
General assembly
Most plants do not fit a template. Some lines move, some cells batch, some stations have instruments and some have an operator with a spanner. Trace is configured to the line you actually have.
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.
| Enterprise MES suite | Local AIDC integrator | ElectronIx Trace | |
|---|---|---|---|
| Certification and validation | Validated deployments in regulated industries | Some hold ISO certification as a business | None. We are built to produce audit evidence, not certified |
| ERP connectors | Deep, supported SAP and Oracle integration | Often have a connector to the ERP you run | None built. A documented seam, which is not the same thing |
| Support organisation | Global, tiered, 24/7 available | Local, on site within days | One engineer, in one time zone |
| Works with the network down | Usually assumes uptime | Usually stops capturing | Durable local spool first, network second |
| If billing lapses | Varies, rarely stated | Project is bought outright | Production capture continues. There is no state that stops it |
| Process values per unit | Yes, with configuration effort | Usually scan events only | Torque, grease, readings, with limits and the instrument |
| Recall query | Supported, often a reporting job | Frequently a change request | Indexed lookup, by lot and by machine and time window |
| Record integrity | Access control, audit logs | Ordinary editable tables | Append-only in the database, hash chained per unit |
| Time to first line live | Months to quarters | Bespoke build, schedule varies | Two to three weeks from walkthrough |
| Commercial model | Per user and per module, plus implementation | Project fee, then change requests | Quoted 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.
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.
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.
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.
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.
Phone and WhatsApp
+91 94882 33115