Progress reports are still typed into Excel every morning
Hand counts and paper logs mean that by the time managers see them, yesterday's problems are already too late.
→ MES & automated data collectionManufacturing System Development · AI · Automation
The answer to factory DX is already in your shop-floor data.
Connect production, quality and equipment data, and turn what you cannot see on the shop floor into what you can. From MES and production management system development to AI, BAP supports you end to end.
ISO 27001
ISO 9001
Privacy Mark (P-Mark)
500+ employees · offices in 5 countries
Trusted by 100+ businesses
…10 years delivering for Japanese companies, across 9+ countries
Why factory data, why now
Factory data infrastructure: the "4th utility" after electricity, water and gas
As smart factory initiatives advance, factory data infrastructure now stands alongside electricity, water and gas as an essential utility. AI, IoT, automation and cybersecurity are shifting from one-off projects to always-on services you simply plug into.
BAP designs, builds and operates the right data infrastructure for your plant, from sensors, networks and MES/WMS to AI.
INDUSTRIAL PARK — UTILITY BOARD
01/2026
ELECTRICITY
415 V · 50 Hz
WATER
supply OK
GAS
pressure OK
DATA ← NEW
● live · BAP
Sound familiar?
What most factories lack is not AI, but visibility into shop-floor data.
Start with the six on-site problems that quietly cost you money every day. Each has a simple fix.
No one can state today's OEE with confidence
Downtime is estimated, not measured, and two departments report two different utilization rates for the same line.
→ IIoT monitoring320 boxes in the system, 296 on the floor
Excel tracking and manual receiving cause inventory gaps, line stoppages and costly emergency responses.
→ Smart warehouse management (WMS)A Tuesday defect is found on Friday after packing
Manual spot checks catch problems late, putting a whole lot and customer trust at risk.
→ AI visual inspectionA critical machine fails right before shipment
Maintenance runs on gut feeling, and a bearing temperature creeping up for weeks went unnoticed.
→ Predictive maintenancePower costs keep rising, but where is the waste?
Air leaks, idle furnaces and aging motors stay hidden without line- and shift-level metering.
→ Energy monitoringOur solutions
Manufacturing system development that raises your ROI
BAP is not a software reseller but a technical partner, from design to system integration. We start with "the smallest step that pays off."
MES (Manufacturing Execution System)
Manage data collection, lot traceability and OEE on one screen, and integrate with your existing ERP.
WMS (Warehouse Management System)
Accurate inbound, outbound and inventory control with barcodes and RFID, including FIFO and expiry management.
Industrial IoT & equipment monitoring
Retrofit sensors onto legacy equipment to monitor operations in real time, with instant alerts on anomalies.
AI visual inspection & predictive maintenance
Apply AI only where ROI is clear, and validate with a small PoC before scaling.
Data platform & OT security
A data backbone connecting MES, WMS and ERP, plus network safeguards for the factory floor.
Legacy system migration
Replace Excel macros, Access databases and end-of-support systems with web systems, without stopping the line.
How we work
Factory DX in five steps, from site survey to operational handover
We start by understanding your current state, narrow down the issues, test small, then scale. Every phase has clear goals and evaluation criteria, so you avoid wasted investment.
01
Current-state survey (interviews & process analysis)
On site or online, we review business processes and existing systems and identify the issues to solve first.
02
Pilot (PoC)
We trial on a single line or area, measure results against pre-agreed criteria, and decide whether to scale.
03
Rollout & system integration
Phased deployment, integrated with your ERP and existing systems, with minimal disruption to production.
04
Operations support & improvement
Technical support, system monitoring and continuous improvement, with support scope and SLA clearly defined.
05
Training & handover
Training, manuals and knowledge transfer so your team can run the system on its own.
The right solution. Transparent cost. Measurable results. Every PoC is evaluated on results, cost and scalability. We prioritize proposals that fit your needs, reuse your existing systems and avoid unnecessary investment.
Industries
Built for the plants of Vietnam, Japan and Thailand.
We focus on industries where we already speak the vocabulary — the standards, the failure modes, the seasonality.
Automotive Parts
- Production records kept to IATF 16949 documentation discipline
- Error-proofing (poka-yoke) support with sensors & checks
- Faster traceability responses for customer and OEM audits
Coffee & Agro-Processing
- Coffee traceability: lot tracking from farm intake to roasted bag
- Moisture, roasting and yield data by batch
- Season-peak capacity planning that survives harvest rush
Electrical & Electronics
- Component-level SMT traceability and serial tracking
- SMT / assembly line monitoring and test-data capture
- Alerting on yield drift before it becomes scrap
Food & Beverage
- Batch & lot traceability from raw material to carton
- Expiry and FIFO control in warehouse and picking
- Hygiene-safe, audit-ready production records (HACCP-friendly)
Furniture & Woodwork
- Panel yield and nesting data per board and per cutter
- Kiln and storage humidity monitoring before panels warp
- Kit-completeness checks so site deliveries never miss a part
Plastics & Rubber
- Injection molding monitoring: cycle times and mold-level tracking
- Scrap and cavity analysis per machine, per shift
- Energy per part — the number nobody had before
Another industry?
Every plant manages the same four things: machines, materials, people and time. Tell us about your line — we will tell you plainly whether we are a good fit.
Factory AI Academy
"Not just training": AI upskilling for your factory
Installing tools is easy. The hard part is building people who can use them on the shop floor. Our trainers visit your plant and work alongside your staff in Japanese, Vietnamese and English, until AI becomes part of daily work, not a training memory.
The Academy promise: every participant finishes with at least one work-ready deliverable (a report template, handover document, checklist app, inspection script and more). Real results, built in real work.
For operators & team leaders
Use ChatGPT and Claude for daily reports, handovers, checklists and Japanese-Vietnamese-English SOP translation, within an approved, secure data environment.
For engineers & QA
Use AI to draft inspection criteria, analyze defect trends and prepare 8D and FMEA documents faster, and understand what computer vision inspection can and cannot do.
For IT & production planning staff
Build in-house tools with Copilot, Claude Code and Codex: report automation and simple apps on MES/WMS data, with the judgment to avoid over-engineering.
1-day on-site workshop
3-month hands-on program
Monthly coaching
Japanese · Vietnamese · English
Inside BAP
Proof, not promises.
Real offices, real people, real milestones — from our HQ in Da Nang to Tokyo, Hanoi and Hue. Come and visit any of them; the coffee is on us.
Why BAP
Japanese quality and solid engineering to support your factory DX
Ten years working alongside Japanese companies
With nearly 10 years of experience and business with more than 100 companies across 5 countries, we deliver technology that fits manufacturing quality requirements and operational needs.
A technical team that understands the shop floor and communicates clearly
Bilingual Japanese-Vietnamese engineers and consultants support you from site survey to rollout. Beyond software design and implementation, we integrate with PLCs, IoT gateways and existing systems.
Results validated with real data
Every project starts from clear goals and evaluation criteria. We measure results with a PoC first, clarify the cost, and only then discuss scaling the investment.
We stay with you beyond go-live, into daily operations
We support post-deployment maintenance, improvement and team training so you can manage the system yourself, and we flexibly handle data storage and security requirements.
FAQ
Manufacturing system development & factory DX: frequently asked questions
We still manage the factory with Excel and paper. Can BAP help?
Yes. Moving Excel and paper-based production management, daily reports and inventory records to an MES (Manufacturing Execution System) and WMS (Warehouse Management System) gives you real-time progress and inventory visibility. BAP starts with a site survey to map your workflows, then digitizes the highest-priority processes step by step, building on your existing Excel practices. We do not force a full replacement overnight.
Our equipment is old, with no sensors or network connection. Can we still collect data?
Yes. By retrofitting sensors and IoT gateways onto legacy equipment, we can collect operating status, cycle time, temperature and power consumption. Equipment with a PLC can often be read directly from the PLC. No equipment replacement is needed, so you can start visualizing OEE (overall equipment effectiveness) with limited investment.
How much does a PoC (pilot) cost?
It depends on scope (number of lines and machines, and the systems to integrate), so we do not quote a fixed price. BAP first clarifies goals and evaluation criteria through a site survey, then starts with a small PoC to limit initial investment. Costs are shown upfront, and you decide on full rollout after seeing results. Contact us for an estimate.
Who owns the data and source code after deployment?
The data is your asset. Rights to the source code and the delivery scope are agreed in the contract. We also adapt to your requirements for data storage (on-premises or cloud) and security.
We already use an ERP (SAP, Dynamics, Odoo, etc.). Do we need to replace it?
No. BAP's MES, WMS and IoT solutions are designed to connect shop-floor data to your existing ERP. They complement what ERPs are weak at, real-time shop-floor data capture, and help you avoid unnecessary investment. We also support API integration and building the data integration layer.
Where should we start with factory DX? Is it feasible for small and mid-sized factories?
Start with a site survey and pick the one problem costing you the most, such as manual data entry, inventory discrepancies or equipment downtime. Even small and mid-sized factories can start small with a PoC on a single line or area, then expand step by step once results are confirmed.
Can you support us in Japanese? Can you deploy in factories in Vietnam?
Yes. Bilingual Japanese-Vietnamese engineers and consultants support you in Japanese from site survey to operations. We also support plants overseas, including in Vietnam, and their integration with your Japanese headquarters.
Do AI visual inspection and predictive maintenance really work on the shop floor?
Yes, when focused where ROI is clear. We validate AI visual inspection, predictive maintenance and demand forecasting with a PoC first, then scale. We also offer the Factory AI Academy, which teaches your staff to use tools like ChatGPT and Claude.
Book a free plant assessment.
60 minutes, at your factory or online. You receive our notes and a prioritized improvement map — free, with no obligation.
What you get
- A senior engineer and a bilingual consultant lead the session.
- Reply within one business day, in Japanese, Vietnamese or English.
- Fixed-scope pilot proposal within two weeks of the visit.
60-min
Diagnosis
1-day
To reply
2-weeks
To proposal