KROT Teaches “Silent” Machines to Talk About Their Work
Developed in Russia, the KROT hardware-and-software platform enables manufacturers to digitize production operations without replacing their existing machine fleet.
The IT team at Kursk Electrical Apparatus Plant (KEAZ) developed the KROT hardware-and-software platform as part of its Industry 4.0 initiative. The system became a key element of the company’s strategy for digitizing “invisible” general-purpose equipment, a persistent challenge for manufacturers where a significant share of machine tools remains outside a unified digital environment.
Digitalization Without Production Interruptions
KROT monitors machine utilization in real time, automatically records downtime and its causes, and then converts raw operational data into actionable analytics. If machine performance was once evaluated only through final output, every stage of operation can now be tracked and measured as it happens.
The platform captures not only production results but also the process itself: when a machine started operating, how long it ran without interruption, why it stopped, and which tool experienced wear. Data from sensors and controllers is transformed into analytics: supervisors can check machine status on a smartphone, managers can view overall line efficiency through dashboards, and process engineers can analyze downtime causes in detailed reports. A previously “silent” machine begins to communicate what is happening on the shop floor, allowing decisions to be based on data rather than assumptions. That is the essence of digitalization - not simply automating recordkeeping, but making every hour of machine operation transparent, manageable, and useful for improving productivity.
The solution’s architecture is entirely Russian, including proprietary controllers, a data-processing server, integration with 1C, mobile interfaces, and a real-time notification system. KROT was built on a Russian hardware and software stack: its software is included in the Russian Software Registry, while the controller is protected by a patent.
The results have been impressive. Response time to equipment stoppages has fallen from 15 - 30 minutes to less than one minute, overall equipment effectiveness (OEE) has reached 80%, and production output has increased by 15%.
At this stage, KROT has become a core component of KEAZ’s digital infrastructure. The platform has been deployed on 125 pieces of equipment across more than 10 workshops and production areas, including metalworking, stamping, electroplating, and assembly operations. Current deployment covers approximately 46% of the plant’s target machine fleet. By the end of 2026, KEAZ plans to connect another 150 machines. The next phase includes three major initiatives: implementation of digital maintenance and repair management, expansion of MES-level functionality, and broader analytics capabilities with predictive features. Together, these steps will move the company from equipment monitoring toward full lifecycle management.
A New Formula for Import Substitution
Before March 2022, Western MES platforms accounted for as much as 65% of the market, although Russian solutions had already reached a 45% share. Today, the direction has shifted as Russian manufacturers actively replace Western systems with domestically developed MES platforms. The market is led by vendors including 1C, Tsifra, Galaktika, ASKON, CSoft, IndaSoft, and other developers.
Industry projects demonstrate the effectiveness of that transition. At UEC-Saturn, for example, the Smart Workshop initiative built a digitally managed production environment using the ZIIoT platform and Tsifra Group’s Dispatcher system. In just six months, productive equipment operating time increased by more than 10,500 hours. Meanwhile, the digital maintenance and repair solution from KOBLiK GROUP reduced downtime by 31%. These examples show how targeted digitalization can directly increase manufacturing output.
In 2024, KAMAZ completed deployment of its PIFI automated production monitoring and control system at the forging and press division of its Naberezhnye Chelny forging plant. PIFI can integrate with ERP, APS, IIoT, robotic systems, industrial production lines, and manufacturing equipment. The practical benefits of MES implementation include greater operational visibility, lower operating losses, and faster business processes.
KEAZ’s experience demonstrates that digitalization does not have to be comprehensive or prohibitively expensive from the outset. Manufacturers can begin at the machine level, gradually connecting equipment, collecting data, and making decisions based on facts rather than intuition while improving labor productivity. Instead of purchasing an expensive foreign MES platform or replacing its machine fleet, the company has developed a solution tailored to the plant’s actual operating needs. For Russia’s IT sector, that sends an important signal: demand is strongest not for abstract platforms, but for practical tools that deliver measurable business results.
Industry 4.0 Without Shock Therapy
Globally, MES platforms have long been viewed as one of the foundational technologies of Industry 4.0.
The global MES market is growing by roughly 10% annually and is expected to reach $29.16 billion by 2030. Russia is following a similar trajectory. Forecasts suggest that by 2030, the Russian manufacturing execution systems market will expand by nearly 70% compared with 2024, reaching 19.78 billion rubles (approximately $278.5 million) with an average annual growth rate of 9%. Demand for digital production-management systems is strongest among discrete manufacturers. Machinery and instrument-making companies already account for more than 40% of MES deployments, followed by energy, metallurgy, and food-processing enterprises.
KEAZ’s approach is unusual because the factory was not adapted to software requirements. Instead, the tool was designed around real production needs. That creates substantial potential for broader adoption, including exports to EAEU countries, CIS markets, the Middle East, and Asia, where demand is rising for affordable modernization of existing production facilities without large-scale machine replacement. Expanding internationally, however, will require product standardization, a complete documentation package, and a well-developed partner network. For now, the company remains focused on scaling the solution domestically. More broadly, KEAZ’s project aligns with Russia’s digital-economy objectives by accelerating the transition to modern manufacturing while maintaining a clear focus on import substitution.
