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Manufacturing Execution System

Our proMES™ solutions are designed to elevate data collection by providing advanced capabilities for manufacturing customers who seek more than just basic MIS solutions. These customers require the ability to instantly analyze shop floor production efficiency, taking into account multiple factors such as real-time machine performance, operator involvement, quality, and maintenance. The proMES™ solution enhances transparency across production processes and effectively bridges the gap between ERP and automation systems, offering a comprehensive approach to improving operational performance.

MES Solution Details
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Problem

  • Manufacturing operations are NOT agile (efficient enough) to respond quickly to changing process events, customer requirements, market conditions and equipment status
  • OEE/KPI calculations only done per machine and not for the whole Process. Also missing for the plant as a complete unit
  • OEE/KPI missing for Labour performance measurement
  • ERP KPI based on assumed values
  • No Realtime KPI data available for quick resolutions
  • No Realtime material consumption patterns available for just-in-time manufacturing
  • Integration with Legacy Systems: Connecting AI-driven solutions with existing manufacturing systems and technologies can be complex and costly.
  • Accuracy of Predictions: Developing accurate predictive models that can reliably forecast potential failures or inefficiencies is difficult, especially when dealing with dynamic environments.

Solution

  • Our solution works on 15-year-old open and customizable platform called "Opera MES"
  • Automate the production processes by integrating machines, sensors, measurement tools, equipment, devices, SCADA, HMI. terminals, printers, etc to the network
  • Equip operators with PCs, tablets, smartphones, etc. that must be connected to the network and be constantly online
  • Abolish “Pens and Papers” to transmit information, that means, to avoid sending information like designs, instructions, notes to operators on papers, reporting any information by filling up paper document and identifying any type of material trough labels, etc
  • To ensure IT systems like Quality, Maintenance, LIMS, etc connect machines and people in line with Industry 4.0 concepts
  • Seamless dynamic integration of data between Shop floor and ERP
  • Utilize advanced neural networks and machine learning algorithms to process and analyze large datasets, making sense of complex manufacturing environments.
  • The Opera platform provides out-of-the-box compatibility with existing manufacturing systems, enabling smooth data flow between legacy technologies and modern AI-driven analytics.
  • Implement AI-driven predictive models that continuously learn and adapt to optimize factory operations, anticipate failures, and suggest proactive improvements.

Benefit

  • MES can reduce manufacturing cycle time by an average of 45%
  • MES can reduce data entry time, usually by 75% or more
  • MES can reduce Work in Progress (WIP) an average of 24%
  • MES can reduce paperwork between shifts an average of 61%
  • MES can reduce lead time by an average of 27%
  • MES can reduce paperwork and blueprint losses an average of 56%
  • MES can reduce product defects an average of 18%
  • Seamless Shop floor to ERP/SAP Integration
  • By predicting potential issues before they arise, Opera helps optimize production schedules, reduce downtime, and improve overall efficiency.
  • With real-time insights and predictive analytics, decision-makers can proactively address problems, improving operational agility and reducing risks.
  • Proactive maintenance and optimized resource usage minimize waste and reduce the likelihood of costly unplanned outages or inefficiencies.
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SOLUTION

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