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Capability · L3

MES & Manufacturing Operations

Manufacturing Execution Systems that replace job cards and paper records with guided execution, genealogy, quality and live performance data.

01The business problem

Production runs on job cards, paper batch records and spreadsheets. WIP is captured late, genealogy is incomplete and nobody sees order readiness until someone walks the floor.

02The technology

  • Execution & dispatch: work orders, routings, step-by-step operator guidance
  • Electronic records: eBR / eDHR with e-signatures, audit trails, review by exception
  • Genealogy & traceability: serial and lot genealogy from raw material to shipment
  • Quality & SPC: in-process checks, automatic holds, deviation workflows
  • OEE & performance: automatic downtime capture, reason codes, shift dashboards
  • Materials, weighing and ISA-88 recipes with parameter download to the PLC
  • ERP integration: orders down from ERP, confirmations and consumption back up

03How it works

  1. Step 1

    Map

    Model your plant and processes against ISA-95 and capture user requirements line by line.

  2. Step 2

    Configure

    Configure a COTS MES or build on reusable frameworks — whichever passes the fit, cost and exit tests for your scope.

  3. Step 3

    Connect

    Integrate PLC/SCADA below and ERP above so data flows without re-keying.

  4. Step 4

    Validate & scale

    FAT/SAT and, for regulated sites, computer system validation under GAMP 5 and 21 CFR Part 11. Lighthouse line first, then a template rollout.

04Potential operational benefits

  • Fewer paper records and manual data-entry mistakes
  • A clear view of output, quality and delays for supervisors
  • End-to-end traceability to investigate defects and complaints faster

Benefits depend on scope, data quality and adoption; we agree measurable targets during discovery.