MES Solutions

Manufacturing Execution Systems That Connect the Shop Floor to the Top Floor

Every part serialized, every station accounted for, every shift reported — automatically. We build MES for high-volume discrete assembly where traceability and performance visibility are non-negotiable.

Discuss an MES Project Packaged vs. Custom
Assembly line stations with serialized production tracking displays
Serialized tracking · genealogy · shift performance
MES DATA FLOW PLANT → ENTERPRISE
Screenshot: MES production tracking screen — add real capture
Capabilities

The Four Pillars of Our MES Delivery

Production tracking & traceability

Know exactly which components went into every serialized unit — across stations and across lines.

  • Serialized part tracking from load to unload
  • Component genealogy — the digital history card for every unit
  • Cross-line component linkage (sub-assembly to final assembly)
  • SAP key component booking integration
Genealogy record

UNIT  : GBX-24A-081847
ST-20 : BRG-LH 7719-A ✓
ST-20 : BRG-RH 7719-B ✓
ST-30 : TORQUE 48.2 Nm ✓
ST-50 : LEAK PASS 0.8 Pa
SAP   : BOOKED 261 mvt

Shift & performance management

Shift boundaries handled automatically, performance metrics computed continuously — no manual spreadsheets.

  • Shift window management with automated shift reset and boundary handling
  • OEE and OLE calculation from live station data
  • TAKT time monitoring against plan
  • SPR (station performance rate) tracking to find the true bottleneck
Shift metrics

SHIFT A : 06:00–14:00
PLAN   : 480  ACT: 461
OEE    : 84.7%
TAKT   : 58s (plan 60s)
BOTTLENECK: ST-30 (SPR 91%)

Production reporting

The right report, in the right inbox, at the right time — without anyone compiling it.

  • Automated per-shift production reports
  • SSRS reports for traceability, rejects, and downtime analysis
  • Scheduled HTML email reports with data tables and charts
  • Management dashboards for daily and monthly review
Delivered automatically
  • Shift-end email
  • Daily summary
  • SSRS drill-down
  • Downtime Pareto
  • Reject analysis

Reports render as clean HTML email — readable on a phone during the morning review meeting.

Quality & validation

The system enforces the process — wrong part, wrong sequence, or missed checkpoint stops the line before a defect moves on.

  • IPQC checkpoint tracking with enforced completion
  • Production order validation before station start
  • Product genealogy validation at every station
  • Poka-yoke station interlocks — e.g., pressing operations with LHS/RHS component validation
  • Alerting via messaging webhooks (Google Chat) and email
Interlock example

ST-20 PRESS · CYCLE START
SCAN : BRG-7719-B
EXPECT: RHS BEARING
CHECK : MATCH — PRESS ENABLED
// mismatch → press inhibited,
// Andon CALL + chat alert

Regulated Industries

Compliance-Grade MES and Material Management

For pharmaceutical, biotech, and other regulated production, the system itself must enforce and evidence compliance — not a binder of SOPs.

21 CFR Part 11 compliance

  • Tamper-evident audit trails on critical records and operations
  • Electronic signatures with user authentication and role-based access control
  • Data integrity aligned to ALCOA+ expectations
  • Validation documentation support (IQ/OQ) for audit readiness

Warehouse Management System capabilities

  • Inventory tracking integrated with production consumption
  • Barcode-driven material movement — receipt, put-away, issue to line
  • Location and batch/lot visibility for traceability
  • Stock reconciliation reports tied to the same SQL Server backbone
Engagement models

Packaged for Speed, Custom for Fit

MES Starter Package

Fast deployment, proven scope

A pre-architected MES core deployed and commissioned in weeks, not quarters.

  • Serialized production tracking
  • Andon board and line dashboards
  • Shift management with automated reporting
  • OEE/TAKT metrics out of the box
  • Standard SQL Server data model

Best for: a first MES on one or two lines, or replacing manual production logs.

Fully Custom MES

Tailored to your process

Designed around your product structure, station logic, and enterprise systems.

  • Tailored data model and genealogy structure
  • ERP/SAP integration (key component booking, order sync)
  • Bespoke workflows — rework loops, quality gates, cross-line linkage
  • Custom poka-yoke and interlock logic per station
  • Custom reporting suite (SSRS, email, dashboards)

Best for: multi-line plants with traceability audits, ERP integration, and complex assembly logic.

Next step

Not Sure Whether You Need Packaged or Custom?

Walk us through your lines and your traceability requirements — we'll tell you honestly which fits.

Request a Consultation Read the EV MES Case Study