MES system
MES system for production management.
We connect the production plan, the warehouse and maintenance with what is really happening on the lines. We deploy our own MES system with planning, warehouse and TPM maintenance modules and connect it to your machines, PLCs and ERP.
ERP knows what to make. MES knows what is being made right now.
An MES system is the layer between the company ERP and the machine control systems. ERP knows the orders and stock, the PLC knows the state of the machine, but nobody sees how the plan is really being met, where downtime occurs and why the line is not reaching the expected output. Without it, production data is pieced together by hand from paper reports and spreadsheets, late and with errors. MES closes this gap, and management sees plan fulfilment and machine status without waiting for the month-end close.
We deploy our own production-focused MES system, developed by our engineering partner. It has three core modules: automatic production planning and scheduling, warehouse management and TPM maintenance. The modules can be deployed together or separately, for example starting with maintenance and adding planning later. Data is collected from machines automatically from the PLC and historian; the operator only adds what the machine cannot know by itself, such as the reason for a stoppage.
The maintenance module records preventive and corrective maintenance, operator fault reports, the shutdown plan and maintenance work done, and evaluates OEE, MTBF, MTTR, downtime and machine costs. It can trigger preventive tasks by calendar or by running hours directly from the control system. We deployed it this way, for example, at a heating plant with CHP units, where the maintenance plan is linked to the scheduling of electricity and heat generation. Maintenance staff receive alerts by e-mail and SMS.
What an MES system brings to production.
Production planning and scheduling
Automatic scheduling of orders to lines and machines based on capacity, due dates and planned shutdowns. Production sees any plan change immediately.
Warehouse management
Tracking of materials, work in progress and finished goods linked to production orders. You know exactly what is in stock and what is in production.
TPM maintenance in the MES system
Preventive maintenance calendar, operator fault reports, approvals and records of maintenance work in one place, with e-mail and SMS notifications.
Downtime and OEE
Collection of downtime from machines, including reasons, and calculation of OEE, MTBF and MTTR by line, shift and machine.
Machine and equipment register
A tree structure of machines and equipment with documentation, intervention history and contacts for external service providers.
Reporting and analysis
Tables, charts and trends for production and maintenance management. Machine costs and plan fulfilment without collecting data by hand in spreadsheets.
What the delivery includes.
We deploy MES as a project, not as off-the-shelf software. It includes the connection to your machines and systems.
- Analysis of production processes and architecture design
- Set-up of the machine, equipment and line structure
- Connection to PLC, SCADA and historian for automatic data collection
- Integration with ERP and other business systems
- Transfer of existing maintenance plans and records
- E-mail and SMS notifications for key staff
- User training and support during ramp-up
- Operation, support and further development of the system
Standards and technologies
How we introduce MES.
Analysis
We walk through production, maintenance and the warehouse with you, map the data flows and define the indicators you want to track.
Pilot
We first deploy the system on one line or in one module, for example maintenance, and validate it with real users.
Roll-out
Once the pilot is debugged, we connect further lines and modules and link MES to ERP and the control systems.
Support and development
We train users, monitor adoption and adapt the system as your production changes.
Related services.
Production data collection
Historisation of data from PLCs and meters, high-availability historian, visualisation, reporting and remote monitoring.
PLC programming
PLC control systems, HMI operator panels and SCADA for Siemens, Rockwell, ABB, Omron and Schneider.
Automation service
24/7 service for PLCs, drives, HMIs, robots and cameras. Contract service, remote access and valve actuator refurbishment.
Frequently asked questions.
Did not find your answer? Write to us and we will reply within 24 hours.
How much does an MES system cost?
It depends on the number of lines and machines, the chosen modules, the data collection method and ERP integration. The maintenance module on its own is a different investment from complete production planning across several halls. We give a fixed price after process analysis and architecture design.
What is the difference between ERP and MES?
ERP runs the company: orders, purchasing, stock and accounting. MES runs production in real time: what is being made on which line, at what output, what the downtime is and what state the machines are in. The two systems complement each other and exchange data.
How long does it take to implement an MES system?
It depends on the scope and on the current state of your data. That is why we start with a pilot on one line or in one module and add further parts in stages, so production does not have to change everything at once.
How does MES calculate OEE?
OEE is the product of availability, performance and quality. MES takes downtime, part counts and scrap directly from the machines or from operator reports and calculates the indicator automatically by machine, line and shift.
Can MES be connected to older machines?
Yes. If a machine has no suitable interface, we add a communication module or pick up signals directly from the PLC or sensors. Older lines then report downtime and part counts just like new ones.
What is TPM maintenance?
TPM, total productive maintenance, combines planned preventive maintenance with the involvement of operators, who report abnormalities themselves and carry out basic machine care. MES records all these activities, schedules them in the calendar and evaluates their impact on downtime and OEE.
Where are you missing production data today?
Tell us how many lines you have, which ERP you use and what you want to track. We will get back to you within 24 hours with a proposal on where to start with MES so it delivers results as soon as possible.