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LinePlanIndustrial Architecture

MES: From Production Order to OEE on a Single Screen

Starts the shift with order and component verification; closes the loop with camera/PLC signals, material consumption, billet/coil/pallet confirmation, quality inspection, and downtime logging. Production, quality, warehouse, and maintenance teams work from the same data layer.

Launch Interactive MES SimulationRequest Architectural Assessment

01 — Stakeholder Value Matrix

Stakeholder & Operational Value Matrix

  • Shift Supervisor

    Operational Requirement: Recording stoppage reasons retrospectively at the end of a shift lowers data accuracy and prevents reconciliation between PLC-detected stops and operator logs.

    Architectural Solution & Value: Operators classify stoppages in 3 touches on industrial panels; the system merges automatic PLC micro-stops with root-cause codes and generates the shift handover report.

  • Production Operator

    Operational Requirement: Multi-step standard ERP transactions cannot keep pace with shop-floor takt times, leading to posting errors during FIFO batch consumption and bulk pallet confirmations.

    Architectural Solution & Value: Station-specific Production Operator Dashboards (PODs), color-coded furnace/line maps, and single/bulk pallet confirmation screens eliminate manual entry errors.

  • Quality & Metallurgy Engineer

    Operational Requirement: Keeping spectrometer analyses, tensile tests, NDT crack checks, and SQC quality measurements on paper or disconnected tools slows down batch traceability and usage decisions (UD).

    Architectural Solution & Value: Laboratory instrument readings and periodic quality inspections flow directly into the active heat, reel, or production order screen.

  • Operations & Planning Management

    Operational Requirement: When actual line speeds, order completion ratios, and shift OEE losses are only visible in next-day reports, in-shift corrective action comes too late.

    Architectural Solution & Value: The Control Tower and Plant Monitoring Cockpit display live speed, active orders, and OEE metrics across every work center in real time.

02 — System Preview

Shop-Floor Interface and Operational Flow

CANLI 16 EKRAN KURUMSAL MES & SCADA
16 Ekranlı MES Simülasyonunu Başlat →
2 Tesis · 14 İstasyon Canlı SCADA, OEE, Operatör Terminali ve Kalite/SPC

2 Tesis · 14 İstasyon Canlı SCADA, OEE, Operatör Terminali ve Kalite/SPC

Gerçek zamanlı telemetri, kök nedenli duruş kaydı, iş emri takibi ve parti soyağacı.

Live Shop-Floor Telemetry and Interface Flow · Reference Data Model

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

02 — Module Scope

Operational Capabilities & Scope

  • Station-Specific Operator Cockpits (POD) & Full Genealogy

    Production orders are tracked step by step at heat, billet, parent reel, pallet, or serialized unit (SFC) level. Physical flow is verified via optical cameras, barcode scanners, and PLC triggers.

  • Single & Bulk Pallet Confirmation + FIFO Component Check

    Validates raw and semi-finished batches scanned at line infeed against FIFO rules, and completes single or bulk pallet confirmations at line outfeed with automatic SSCC/barcode label printing.

  • Rapid Downtime Logging, Split Reasons & Maintenance (PM) Trigger

    Captures machine stops directly from PLCs, allows operators to split extended stoppages across multiple root causes, and opens maintenance notifications automatically for equipment faults.

  • Poka-Yoke Interlocks & Quality Hold Protection

    Alerts the operator and blocks confirmation if an incorrect component is scanned, a preceding routing step is incomplete, or a semi-finished batch lacks quality release (UD).

  • Lab Instruments, LGV Vehicles & Level-2 Automation Integration

    Communicates bidirectionally with meltshop, rolling mill, paper, and packaging Level-2 systems, autonomous LGV vehicles, inkjet coders, spectrometers, and mechanical testing machines.

  • Live OEE Andon, Shift Logbook & Plant Monitoring Cockpit

    Computes Availability, Performance, and Quality multipliers in real time, updates target speeds dynamically upon product changeovers, and summarizes the entire plant on one screen.

Industries & Shop-Floor Applications

How Is the Shop Floor Managed Across Sectors?

Explore all sector architectures →
SECTOR 01Heavy Industry & Primary Metallurgy

Iron & Steel · Meltshop and Continuous Casting (CCM)

Heat-Based Meltshop Cockpit and Automated Consumption/Output Confirmation

Single-screen management of heat orders, ferro-alloy additions and cut billet confirmations across EAF/BOF, Ladle Furnace, Vacuum Degassing and Continuous Casting stations.

Spectrometer Laboratory Integration and Intermix (Mixed Casting) Control

Instant comparison of optical emission spectrometer chemical results against steel grade tolerances and automated segregation of transition billets during sequence casting.

Inspect 5-step shop-floor screen workflow→
SECTOR 02Heavy Industry & Hot Forming

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

Furnace Entry Camera Verification and Billet Charging Interlock

Camera and weigh-scale verification of billets fed by overhead crane into the reheating furnace, preventing mixed-heat charging and preserving traceability for damaged tags.

In-Furnace Billet Thermal Map and SCADA – MES Reconciliation

Live slot-by-slot mapping of all billets inside the reheating furnace by position, order, heat color code, zone temperature and furnace dwell time.

Inspect 5-step shop-floor screen workflow→
SECTOR 03High-Speed Process & Packaging

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

Bulk Pallet Confirmation Engine and In-Memory FIFO Component Simulation

Single-action confirmation of multiple pallets during peak shifts with upfront FIFO component stock validation and automated label/posting orchestration.

Centralized Inkjet Coding and Mixer (Drop) – Line Traceability

Pairing solution batches prepared in mixer vessels with packaging lines and automatically driving line-mounted Inkjet printers from MES.

Inspect 5-step shop-floor screen workflow→
SECTOR 04Continuous Process, LGV & Converting

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

Full Genealogy from Pulp Furnish Blend to Tambour, Parent Reel and Converting Pallet

Continuous material genealogy linking pulp blend ratios to Paper Machine tambour rolls, slit parent reels and finished converting pallets.

LGV (Laser Guided Vehicle) Reel Grouping and Autonomous Line Feeding Integration

Grouping heavy parent reels at the paper machine exit and dispatching LGVs for hands-free transport to intermediate storage and converting lines.

Inspect 5-step shop-floor screen workflow→
SECTOR 05Assembly Lines & Serial Production

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

Station-Based Operator Panels (POD) and Real-Time Poka-Yoke Interlock Engine

Real-time station validation architecture that halts progression when an incorrect component is scanned or an upstream operation is incomplete.

Automated Test Booth Integration and Closed-Loop Rework Governance

Automated capture of electrical and functional test rig results with enforced closed-loop rework routing for failed units.

Inspect 5-step shop-floor screen workflow→
SECTOR 06Electronics & High-Granularity Traceability

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

Component Reel ID, Feeder Slot Interlock and MSD Moisture Floor-Life Governance

Verification architecture preventing wrong component reels from being loaded onto SMD feeders and blocking expired moisture-sensitive components.

AOI / Functional Test Integration and Complete Electronic As-Built Genealogy

Automated linking of optical and electrical test logs to board serial numbers and multi-level genealogy from component reel to final box-build device.

Inspect 5-step shop-floor screen workflow→

03 — Integration

Enterprise Integration Architecture

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
Şekil 1 — ERP ↔ MES ↔ Shared Data Layer ↔ Digital Twin and 3D Warehouse

Data sources: ERP (REST / OData / RFC / Web Services), MES, PLC/SCADA/OPC UA, Level-2 Automation, JDBC, CSV/Excel import.

04 — Infrastructure & Architecture

Technical Specifications & Infrastructure

AttributeSpecification
DeploymentOn-premise, cloud, or hybrid multi-plant architecture
TerminalsIndustrial touch panel PCs (1366x768 / 1920x1080), rugged handhelds, tablets, and desktops
Data Refresh1–5 seconds (PLC/SCADA signal ingestion and UI refresh)
Identity & AccessAD/LDAP, SSO, work-center and role-based screen authorization
IntegrationERP (REST/OData/RFC/Web Services), PLC/SCADA, OPC UA, L2 Automation, Barcode & Lab Devices
Offline ResilienceAsynchronous message queueing and automatic post-outage reconciliation

05 — Delivery Methodology

Delivery & Commissioning Methodology

  1. 01Discovery (1 week): review of production processes, stations, ERP flows, and PLC/L2 signal inventory.
  2. 02Screen & Workflow Design: sequential operator, quality, and supervisory screens from raw material intake to finished warehouse.
  3. 03Pilot Line (2–4 weeks): shop-floor operator rehearsals and shift handover validation.
  4. 04Plant Rollout: full-line commissioning, ERP stock/confirmation reconciliation, and hypercare support.

06 — Corporate FAQ

Architecture & Delivery Processes (FAQ)

It reads production orders, BOMs, and routings via standard web services, REST APIs, OData, or RFC, and posts production confirmations, component consumption, scrap/returns, and quality results back in real time.

07 — Architectural Assessment

Enterprise Architectural Assessment

Launch Interactive MES SimulationRequest Architectural Assessment