Solution
Stop treating the shop floor as a black box: live MES
MES (Manufacturing Execution System) is a shop-floor data layer that collects data from machines, operators and sensors in real time and posts it to the ERP. It removes the disconnect between the planning office and the shop floor; it lets you monitor machine status, operator performance and production quality live.
Challenges you face
Problems in day-to-day work
This module is built to fix the problems below.
- Production reports are collected on paper forms at shift-end, so shop-floor data arrives delayed and error-prone.
- Why machines stop isn't recorded, so stoppage causes can't be analyzed.
- Planning knows what should be produced, but something else happens on the floor, and the gap between them goes unseen.
- Machine-level efficiency (OEE) isn't measured, so where capacity is lost is unknown.
Capabilities
What can you do with Stop treating the shop floor as a black box: live MES?
The module's core features.
IoT-enabled automatic data collection
Connects to machines via PLC, SCADA or external sensors to pull data such as produced quantity, temperature, pressure and speed automatically, without human intervention.
Real-time machine status tracking
See live on your screen which machine is running, which is faulty and which is in setup.
Paperless factory with kiosk and tablet interfaces
Operators see their assigned work orders, technical drawings and quality criteria on touch screens; job start, stoppage reason and finish are recorded with a single touch.
Real-time OEE analysis
Calculate availability, performance and quality parameters in real time to monitor your OEE score live; identify the biggest time-wasting causes with stoppage Pareto analyses.
Machine-level energy monitoring
Measure machine-level energy consumption to track energy cost per product.
Predictive maintenance alerting
Build an early-warning layer that analyzes deviations in vibration, heat or sound data from machine sensors and opens a work order for the maintenance team before a fault occurs.
Outcomes
What it delivers for your business
What you see in daily operations once it is set up properly.
- Shop-floor data is collected in real time, so you don't wait for shift-end to decide.
- Stoppage causes are recorded, so the biggest time-wasters become visible.
- OEE measurement shows each machine's efficiency and where capacity is lost.
- Operators don't fill in paper forms; they record with a single touch on the screen.
- Predictive alerts reduce unplanned stoppages and major repair costs.
FAQ
Frequently asked questions
The module connects to shop-floor devices via PLC, SCADA or external sensors attached to machines and automatically collects data such as produced quantity, temperature, pressure and speed. The integration scope is assessed based on your machine fleet's infrastructure.
OEE is calculated as the real-time product of availability (how long the machine ran), performance (the speed it ran at) and quality (how much of the output was sound), and is monitored on live dashboards.
Shop-floor screens are designed with simple, touch-friendly interfaces for kiosks and tablets. Because job start, stoppage and finish are recorded with a single touch, usage is learned quickly; interfaces can be customized to your workflow with low-code.
The system detects abnormal deviations in sensor data (for example rising bearing temperature or increasing vibration) and warns the maintenance team in advance. It's an early-warning layer; its aim is to reduce the risk of unplanned stoppages.
Let's configure Stop treating the shop floor as a black box: live MES around your business
Get in touch for a demo tailored to your team's needs.