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MES software (manufacturing execution system) shows in real time how the production plan in your ERP is actually being carried out on the shop floor. Work orders, OEE, downtime and scrap are captured from machines, barcode scanners and operator terminals, and shift reports build themselves. It integrates with Logo, SAP, Mikro and bespoke ERPs, or runs on its own.
The work order is open in the ERP and the ship date is set. Yet what really happens on the shop floor is often only known from end-of-shift paperwork and a spreadsheet put together the next morning. Why a machine stopped, where the scrap came from and whether the order will ship on time are answered after it is too late to act.
We build MES (Manufacturing Execution System) software around your lines. Data is captured as production happens, from machine signals, barcode scanners and operator terminals. Output, scrap and downtime per machine are recorded without paper forms. The system connects to your existing ERP and SCADA system, so production actuals do not have to be keyed into the ERP a second time.
Work orders from the ERP, or created in the MES, are assigned to a machine and shift. Operators see the next job on screen, start and finish it, and planned versus actual is compared in real time.
OEE is calculated from availability, performance and quality and tracked live for every machine. Losses are split automatically into breakdowns, set-ups, speed losses and quality rejects.
Every stop is logged with its reason, such as a breakdown, waiting for material or planned maintenance. Operators record scrap quantity and cause, and trend charts point to the source of recurring problems.
You can see which operator produced how much, on which machine and in which shift. Shift comparisons and performance reports are produced without manual calculation.
The raw material batch used on each work order is recorded, enabling backward traceability and material consumption analysis when a quality issue arises.
The end-of-shift report is produced automatically. Daily, weekly and monthly output, OEE trends, the machines with the most downtime and the highest scrap rates are ready on the management screen.
A machine on the press line stops because it is waiting for material. The operator selects the downtime reason on the terminal; on the production manager's screen, that machine's OEE drops and the gap between planned and actual on the work order widens. Material is expedited there and then, or the job is moved to another machine. At the end of the shift the report is ready and production actuals have already gone into the ERP, so nobody spends the next morning chasing forms and spreadsheets.
See which machine stopped and why before the shift ends, and act while it still matters.
Scrap is logged with its cause and batch, so recurring problems are traced with data.
Production and shift data is captured digitally, with no separate forms or spreadsheets to fill in.
Production actuals flow into the ERP automatically, so the same data is never entered twice.
We build MES modules that integrate with Logo, SAP, Mikro or your own bespoke ERP. If you do not use an ERP, the MES can be deployed on its own. To strengthen planning, our production planning (APS) solution works in the same data flow, and our production traceability solution takes batch tracking further. For measurement and nonconformance records see our quality management system, and to prevent stoppages before they happen see predictive maintenance. For staff attendance and shift timesheets, SmartPass runs access control and time-and-attendance on the same card and exports a monthly summary per person to your ERP; to buy it, fill in the SmartPass sales form.
Related guides: MES vs ERP and how they integrate, how to calculate OEE step by step, the line items behind MES software cost. For more, browse our Industry 4.0 guides.
Let us walk your lines together, plan which data comes from which machine and how the ERP link will work, then set out the scope and cost in a written proposal.
MES (manufacturing execution system) software shows in real time how the production plan in your ERP is actually being carried out on the shop floor. Output, scrap and the reason each machine stopped are captured as production happens, from machine signals, barcode scanners and operator terminals. Shift reports build themselves, removing paper forms and the spreadsheet put together the next morning.
ERP plans production: the work order is opened and the ship date is set. MES tracks how that plan is carried out on the floor in real time, recording output, scrap, downtime and production per operator. When MES is integrated with the ERP, production actuals flow back automatically, so the same data is never keyed in twice.
We build MES modules that integrate with Logo, SAP, Mikro or your own bespoke ERP. Work orders from the ERP are assigned to machines and shifts, and actual production is passed back to the ERP. If you do not use an ERP, the MES can be deployed on its own. It can also connect to your existing SCADA system.
OEE (overall equipment effectiveness) is availability multiplied by performance and quality. The MES calculates these three components for every machine in real time and automatically splits losses into breakdowns, setup, speed loss and quality rejects. You can see which machine stopped and why before the shift ends, and act on it straight away.
Every stop is recorded with its reason, such as a breakdown, waiting for material or planned maintenance. Operators enter scrap quantity and reason, linked to the work order and the raw material batch used. Trend charts and the management screen show the machines that stop most and the highest scrap rates, so recurring problems are traced with data rather than guesswork.
We start with a free site assessment: we look at your lines on site and plan which data comes from machine signals, which from operator terminals or barcode scanners, and how the ERP link will work. The cost depends on the number of machines and lines, the ERP integration and the modules you need, and is set out with the scope and phases in a written proposal.
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