I don't see the opportunity.

It doesn't sound like a hacking problem; it sounds like a sales problem. If your customers are so hidebound they won't even use the software they already have, how will you convince them to pay for, let alone use, yours?

Or are you planning to duplicate that effort and sell it to other manufacturers (who I hope can still act rationally)?

If your solution is so compelling and the demand is there, find better customers.

"Good! Another opportunity for a couple of hackers in a spare bedroom."

Right-O.

Agreed. The problem is, hackers don't tend to even have access to this type of problem because you need access to the very real environment of a large factory floor. And, even if you did build a better solution, there are relatively few customers, so selling is really about selling into large corporate bureaucracies, not getting someone to download a cool new plug-in. This type of selling is very expensive, and they will not buy from a couple of hackers in a spare beadroom

Right. Now, change "billion" to "million". Find a little work in one of the thousands of small businesses in your neighborhood, and within 2 weeks you'll find yourself screaming one of two things, either, "Who wrote this &^#$^#&!" or "I can do way better than this."

Congratulations. You just found the basis for a viable start-up.

That I can do!

Those 4 words still send chills up my spine, especially with the exclamation point. (I know, what a nerd.) Hate to get all Oprah on you, but sometimes I think having that attitude is half the battle.