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LinePlanIndustrial Architecture

ERP · MES · DIGITAL TWIN · 3D WAREHOUSE

Integrated Planning, Execution and 3D Digital Twin Architecture for Enterprise Manufacturing Plants.

From order scheduling (APS) and station-level manufacturing execution (MES) to live 3D line telemetry and bin-level warehouse management, every module operates on a unified data model connected to your enterprise ERP and Level-2 automation infrastructure.

LIVE INTERACTIVE SIMULATION DOCK

5 Real-Time Browser-Native Industrial Systems — Click Any System to Launch Immediately:

Open Simulation Center →
Iron & Steel Integrated 3D Twin3D TWIN · 01

Iron & Steel Integrated 3D Twin

EAF/LF/CCM · 112/118 Billet Furnaces · 2 Mills

FMCG 12-Line & Logistics 3D Twin3D TWIN · 02

FMCG 12-Line & Logistics 3D Twin

12 Lines · 6 FIFO Carriers · Robot & Lift

High-Bay 3D Warehouse & Stock Aging3D WMS · 03

High-Bay 3D Warehouse & Stock Aging

5,280 Bins · 6+ Mo Red / 3–6 Mo Orange Heatmap

16-Screen Enterprise MES & SCADAMES · 04

16-Screen Enterprise MES & SCADA

CEO Cockpit · 7 Station SCADA · Quality & SPC

Advanced Production Planning (APS)APS · 05

Advanced Production Planning (APS)

Order Scheduling · Machine Capacity · Setup Solver

LIVE 3D WEBGL DIGITAL TWINS & ENTERPRISE MES SHOWCASE

Sector-Specific 3D Digital Twins, High-Bay 3D Warehouse, and 16-Screen MES Suite.

Inspect full-scale browser-native 3D factory digital twins, the 5,280-bin high-bay warehouse with 6+ months / 3–6 months / 1–3 months stock aging heatmaps, and the 16-screen enterprise MES suite in real time.

Iron & Steel Integrated Plant 3D Digital Twin
DIGITAL TWIN · 01Iron & Steel · Meltshop, CCM & 2 Rolling Mills

Iron & Steel Integrated Plant 3D Digital Twin

Full-cycle 3D simulation from scrap bays, EAF, Ladle Furnace (LF), Vacuum Degassing (VD), and 4-strand CCM to 112/118-billet reheating furnaces, Bar Rolling Mill (PK-...), and Wire Rod Coil Mill (KG-...).

  • 108-min ladle cycle (L-01..L-03) and 4-strand CCM (44 billets/heat)
  • Transparent Inside-Furnace mode (112 and 118 billet FIFO thermal grid)
  • 3 simultaneous active billets per rolling mill and Heat Trace genealogy
Launch 3D Iron & Steel TwinDigital Twin Hub
FMCG 12-Line Production & Pallet Logistics 3D Twin
DIGITAL TWIN · 02FMCG · 12 High-Speed Lines & Pallet Logistics

FMCG 12-Line Production & Pallet Logistics 3D Twin

12 converting and filling lines across 3 machine families (Nonwoven A-01..05, Paper Converting B-01..05, Chemical Filling C-01..02), 6 FIFO material carrier geometries, robot palletizing, and 4-column lift transfer.

  • Overhead 3D OEE rings, 180s stop reason grace rule, and interactive minimap
  • 6 distinct 3D FIFO material carrier geometries behind primary infeed
  • 88 bootstrap pallets (52 waiting on floor + 36 in warehouse) and 144s cycle
Launch 3D FMCG TwinDigital Twin Hub
High-Bay 3D Warehouse & Stock Aging Heatmap
3D WAREHOUSE · 035,280 Bins · Non-Moving Stock Aging Heatmap

High-Bay 3D Warehouse & Stock Aging Heatmap

Analyze bin occupancy and non-moving inventory aging tiers across an 8-aisle, 16-row automated high-bay distribution center with stacker cranes (SRM) and receiving/shipping docks.

  • 6+ months critical non-moving stock (Red) & 3–6 months waiting stock (Orange)
  • 1–3 months normal stock (Yellow), < 1 month active turnover (Green), and empty bins
  • One-click aging tier dimming, aisle camera presets, and WMS inspection drawer
Launch 3D Warehouse TwinModule Architecture
Enterprise MES, Live SCADA & Operator Execution Suite
ENTERPRISE MES · 0416 Screens · 2 Plants · 7 Stations SCADA & Quality

Enterprise MES, Live SCADA & Operator Execution Suite

16-screen industrial MES spanning CEO executive dashboards, plant monitoring, 7 station SCADA mimics, operator confirmation terminals, downtime analysis, quality forms, SPC charts, and lot genealogy.

  • Executive: CEO Dashboard, Factory Monitor, Live Andon, Shift & Downtime Analytics
  • Shop Floor & SCADA: Line Overview, 7 Station SCADA Mimics & 7 Operator Terminals
  • Planning & Quality: Production Orders, Reel/Lot Plan, Quality Forms, SPC & Traceability
Launch 16-Screen MES SuiteMES Architecture

Industrial Verticals · 6 Core Sectors

Sector-Specific Shop-Floor Architecture and Reference Process Flows.

Select your industry to examine how the shop floor is managed step by step—from raw material intake and production lines to quality laboratories and the 3D finished-goods warehouse.

View All Sector Architectures
SECTOR 01Heavy Industry & Primary Metallurgy

Iron & Steel · Meltshop and Continuous Casting (CCM)

Step-by-step execution across raw material preparation, Electric Arc Furnace (EAF) / Basic Oxygen Furnace (BOF), Ladle Furnace (LF), Vacuum Degassing (VD) and Continuous Casting Machine (CCM) stations via operator cockpits, quality panels and a 3D Digital Twin.

SEQUENTIAL SHOP-FLOOR PROCESS FLOW (5 STEPS)

  1. 01Raw Material Preparation, Sintering and Hot Metal / Scrap Charging
  2. 02Primary Smelting (Electric Arc Furnace / Converter) and Desulfurization
  3. 03Secondary Metallurgy (Ladle Furnace - LF & Vacuum Degassing - VD)
  4. 04Continuous Casting Machine (CCM) and Mixed-Grade (Intermix) Casting Management
  5. 05Turnover Cooling Bed, Robotic Barcoding and Semi-Finished Billet Yard

5 Core Stations

Sequential Shop-Floor Flow

25+ Field Screens

Operator & Supervisor UI

Live Analysis & 1640°C

Chemical & Thermal Tracking

Heat → Billet

Traceability

Explore Screens and Process Flow for This Sector
SECTOR 02Heavy Industry & Hot Forming

Iron & Steel · Hot Rolling Mill, Reheating Furnace and Wire Rod / Bar Mill

Rolling mill architecture spanning furnace entry camera verification, in-furnace billet thermal mapping, hot rolling stands, cold shear/saw cutting, non-destructive crack testing (NDT), bundling and 3D finished goods warehouse management.

SEQUENTIAL SHOP-FLOOR PROCESS FLOW (5 STEPS)

  1. 01Billet Selection, Overhead Crane Feeding and Furnace Entry Verification
  2. 02Reheating Furnace Walking-Beam Tracking, 3-Zone Thermal Process and Billet Map
  3. 03Hot Rolling Mill Line, Main Pulpit Tower and Specific Energy Monitoring
  4. 04Cooling Bed, Cold Shear, Abrasive Saw Cutting and Surface/Crack NDT
  5. 05Bundling, Strapping, End Painting, Labeling and 3D Finished Goods Warehouse

5 Core Stations

Sequential Shop-Floor Flow

35+ Field Screens

Operator & Report UI

Single-Billet FIFO

Furnace & Mill Tracking

3D Bay & Rack Matrix

Warehouse & Dispatch

Explore Screens and Process Flow for This Sector
SECTOR 03High-Speed Process & Packaging

Fast-Moving Consumer Goods (FMCG) · Hygiene, Personal Care and High-Speed Packaging

Chemical solution/mixer (Drop) batching, FIFO roll/packaging feeding, high-speed filling and converting, centralized Inkjet coding, bulk palletizing and 3D warehouse inventory reconciliation.

SEQUENTIAL SHOP-FLOOR PROCESS FLOW (5 STEPS)

  1. 01Chemical / Semi-Finished Solution Batching and Mixer (Drop) Process
  2. 02Line Setup, Roll / Packaging FIFO Feeding and Sanitation
  3. 03High-Speed Production, Filling, Centralized Inkjet Coding and OEE Andon
  4. 04Secondary Packaging, Case Packing, Palletizing and Order Completion
  5. 05Floor Buffer Stock, Elevator/Conveyor Transfer and 3D Finished Warehouse Putaway

5 Core Stations

Sequential Shop-Floor Flow

40+ Field Screens

Operator & Supervisor UI

12 Lines + 5 Stages

3D Line & Pallet Flow

3D Rack & Batch

Warehouse & FIFO Control

Explore Screens and Process Flow for This Sector
SECTOR 04Continuous Process, LGV & Converting

Paper & Converting · Tissue Paper, Parent Jumbo Roll and Converting Lines

Pulp furnish blending, Paper Machine tambour/parent roll winding, autonomous reel logistics via Laser Guided Vehicles (LGV), converting lines, Statistical Quality Control (SQC) and finished warehouse operations.

SEQUENTIAL SHOP-FLOOR PROCESS FLOW (5 STEPS)

  1. 01Pulp Raw Material Preparation, Furnish Blend Recipe and Chemical Dosing
  2. 02Paper Machine — Tambour (Parent/Jumbo Roll) Winding and Rewinder Slitting
  3. 03Reel Grouping and LGV (Laser Guided Vehicle) Autonomous Logistics
  4. 04Converting Lines (Perforation, Embossing, Winding, Log Saw and Packaging)
  5. 05Palletizing, Forklift Operations and Finished Goods Warehouse Management

5 Core Stations

Sequential Shop-Floor Flow

45+ Field Screens

Operator & Supervisor UI

LGV Integration

Autonomous Intralogistics

SQC, UD & OEE

Quality & Efficiency

Explore Screens and Process Flow for This Sector
SECTOR 05Assembly Lines & Serial Production

Discrete Manufacturing · Home Appliances, Electromechanical and Automotive Tier-1

Unit-level Shop Floor Control (SFC) assembly management, barcode component interlocks, smart torque/test rig integration and line-side material replenishment architecture.

SEQUENTIAL SHOP-FLOOR PROCESS FLOW (5 STEPS)

  1. 01Press Shop, Metal Stamping and Sub-Assembly Cell Production
  2. 02Body Preparation, Surface Treatment and Paint / Enamel Line Tracking
  3. 03Multi-Station Assembly Lines, Barcode Component Validation and Poka-Yoke
  4. 04Electrical Safety, Performance Test Booths and Closed-Loop Rework Routing
  5. 05As-Built Unit Genealogy, Rating Plate Printing, Packing and Dispatch

5 Core Stations

Sequential Shop-Floor Flow

Unit Serial No (SFC)

Traceability Unit

Real-Time Interlock

Error Proofing (Poka-Yoke)

Standard POD Template

Multi-Plant Architecture

Explore Screens and Process Flow for This Sector
SECTOR 06Electronics & High-Granularity Traceability

Electronics, Surface-Mount (SMD) PCBA and Precision Device Manufacturing

Electronic component reel verification, Moisture Sensitive Device (MSD) floor-life tracking, SMD pick-and-place, AOI/functional testing, firmware loading and full As-Built Genealogy.

SEQUENTIAL SHOP-FLOOR PROCESS FLOW (5 STEPS)

  1. 01SMD Component Preparation, Reel-to-Feeder Verification and MSD Floor-Life Tracking
  2. 02Laser PCB Marking, Solder Paste Printing, SMD Placement and Reflow Oven
  3. 03Automated Optical Inspection (AOI / X-Ray) and Visual Defect Classification
  4. 04In-Circuit Test (ICT), Firmware Flashing and Functional Calibration
  5. 05Final Box-Build Device Assembly, Electronic As-Built Genealogy and Packing

5 Core Stations

Sequential Shop-Floor Flow

Reel ID & MSD

Component Control

AOI · ICT · FCT

Test & Diagnostics

Reel → Final Device

Genealogy Depth

Explore Screens and Process Flow for This Sector

Live Shop-Floor Telemetry and Visualization

Monitor your manufacturing floor in 3D. in 3D

Work orders, production confirmations, downtime tracking, and bin-level inventory control converge in a unified data model. Enterprise ERP, MES, Digital Twin, and 3D Warehouse layers operate alongside PLC/SCADA/OPC UA signals under a tailored project and SLA governance model.

Launch Interactive SimulationSchedule Architecture Review

Bin · A2-R07-C03-L2

Occupancy 82%

Wire Rod Coil 12x1.5 · 1,420 kg

Occupancy 82%
6+ Mo Inactive3–6 Mo1–3 Mo< 1 Mo ActiveEmpty
Reference data · 5,280 bins
Shop-floor architecture experience
10+ Years
International delivery
8 Countries · 16 Plants
Full-cycle implementations
11 MES

System Architecture

Enterprise IT/OT and ERP–Shop-Floor Integration Architecture.

Enterprise ERP and MES business rules exchange data bidirectionally; operator terminals, the Digital Twin, and the 3D Warehouse read from the same unified data layer while PLC/SCADA/OPC UA signals stream in continuously.

Integration ArchitectureBi-directional data exchange between ERP and MES; operator screens, Digital Twin and 3D Warehouse read from the shared data layer; PLC, SCADA and OPC UA signals feed the data layer.REST / OData / RFCLive Data StreamShared modelEnterprise ResourceERP System (PP / MM / WM)Orders · Inventory · Master dataManufacturing ExecutionMES & Business Rules EngineWork order · Confirmation · OEEUnified Record ChainShared Data LayerLive state & historical traceOperational InterfacesAPS & MES ScreensVisual Shop-Floor ModelDigital Twin & 3D WarehouseShop-Floor AutomationPLC · SCADA · SensorsIndustrial ProtocolsOPC UA · Modbus TCP · REST

Supported interfaces: REST API · OData / RFC · OPC UA · Modbus TCP · JDBC · CSV/Excel

System Architecture

Enterprise ERP & Planning Layer

Production orders, BOMs, routings, material master records, and goods movement postings (101/261) stay synchronized via RFC, IDoc, OData, and REST services.

System Architecture

MES, Digital Twin & 3D Warehouse Core

Station POD screens, SFC/batch genealogy, OEE calculation engines, and 3D WebGL scenes operate on a single transactional database and message queue.

System Architecture

Level-2 Automation, PLC & Lab Devices

OPC UA/DA, S7 PLCs, Level-2 meltshop/rolling mill servers, LGV vehicles, industrial barcode cameras, and spectrometers connect directly to shop-floor workflows.

Industrial Field Guides

Shop-Floor Engineering Publications and Architectural Insights.

Technical deep dives on ERP–MES reconciliation, Level-2 automation integration, 3D digital twin telemetry, and high-availability shop-floor architecture.

Browse All Publications

About Us · Field Portfolio

10+ Years of International MES and Shop-Floor Engineering.

Across iron and steel, home appliances, fast-moving consumer goods, paper/converting, electromechanical, and electronics industries, we have delivered enterprise MES, advanced planning, 3D digital twin, and Level-2 automation integration projects for 16 manufacturing plants in 8 countries.

About UsConsulting ServicesLinkedIn

Selected Field Projects (8 Countries · 16 Manufacturing Plants)

  • Scrap yard, meltshop, wire rod, and rolling mill MES implementation for iron and steel plants in Algeria and Turkey.Algeria & Turkey · Iron & Steel
  • High-speed packaging line MES and equipment integration for FMCG plants in Belgium, Morocco, and Turkey.Belgium, Morocco & Turkey · FMCG
  • Multi-plant MES migration and production order synchronization for a home appliance facility from Romania to Turkey.Romania & Turkey · Home Appliances
  • ERP–MES–Automation integration for electromechanical and electronics manufacturing facilities in Turkey and Greece.Turkey & Greece · Electronics
  • Manufacturing execution and shop-floor equipment integration for machinery and food & beverage plants in Italy, Germany, and the Netherlands.Italy, Germany & Netherlands · Industrial

In accordance with corporate non-disclosure agreements (NDAs), client trade names and financial metrics are anonymized.

Enterprise FAQ

Architecture, Integration and Commissioning Processes.

Our architecture integrates bidirectionally with your enterprise ERP layer via REST APIs, OData, RFC/BAPI, IDoc, or database views. It reads production orders, BOMs, and routings, and posts confirmations, downtime records, component consumption, and inventory movements back to your system in real time.

Architecture Discovery & Roadmap

Let Us Design the Target Architecture for Your Manufacturing Plant.

In a technical architecture review session, we evaluate your current ERP, MES, and shop-floor automation landscape and define a phased commissioning and integration roadmap tailored to your facility.

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