Low-cost production visibility for small and mid-sized manufacturers.

Star Chart Systems is building a simple way to see how work actually moves through a factory. We use tags, elevated sensors, and software to turn physical movement into useful production data.

What we are building

Most production tracking systems are expensive, hard to install, low resolution, or painful for teams to adopt. Many manufacturers still rely on manual checks, barcode scans, spreadsheets, or one-off lean studies to understand where time is being lost.

Star Chart Systems is a bolt-on visibility layer for the production floor. Small tags travel with parts, elevated sensors locate those tags, and the software turns that movement into real-time flow data.

The goal is not to replace every MES or ERP system. The goal is to give manufacturers a clearer view of product flow without cameras, heavy integrations, or a long implementation project.

What it helps with

We are focused on practical factory questions: where parts wait, where work backs up, how far products travel, and which steps create avoidable delay.

  • Real-time production flow visibility
  • Transportation waste reduction
  • Bottleneck detection and diagnosis
  • Live value stream mapping
  • Layout and process improvement
  • Compliance and audit history
  • Safety and floor oversight without camera-based monitoring
  • Data foundation for future digital twin work

The first customer profile is a small or mid-sized manufacturer with complex parts, low-to-medium production volume, and a real need to understand product movement across many steps.

Where we are

Star Chart Systems is early. We are building the MVP, validating the hardware-to-software flow, and looking for pilot environments where the problem is clear enough to test quickly.

The first version is meant to answer a basic but valuable question: what path did work take through the facility, where did it wait, and what does that reveal about the process?

We are most interested in manufacturers willing to test a focused pilot around bottleneck detection, search time reduction, layout improvement, or production flow visibility.

Team

Peter J. Gibbons

Co-founder

Peter works on the technical systems behind Star Chart Systems, including hardware, infrastructure, and operations. He has experience as Chief Electrical Engineer at IrishSat and in operations infrastructure for technical teams.

His background is in building systems where hardware, software, people, and process all have to work together in the real world.

Alex Archer

Co-founder

Alex works on process engineering, manufacturing operations, and supply chain systems. He previously worked as a Process Engineer at Intel and in supply chain industrial engineering at Boeing.

His background is in improving complex production processes, reducing waste, and making operations easier to measure and manage.

Contact

We are looking to talk with manufacturers, operators, industrial engineers, and advisors who care about better production visibility.

Email: petergibbons7@icloud.com