Service

MES and OEE system implementation

We implement production tracking that calculates OEE from the machine itself, not from paper forms. Work orders, downtime reasons and scrap come from the operator panel; counts and states come from the machine.

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Our clients

Siemens
Anadolu Isuzu
BSH
Tofaş
Toyotetsu
Martur
Turkcell
Vodafone
Doğadan
Pakmaya
Bross
Abdi İbrahim
Nobel İlaç
Plastimak
Dalgıç Kalıp
Barbaros Motor
Magneti Marelli
Rözmaş
Sanel

A Manufacturing Execution System sits at ISA-95 Level 3, between the plan in the ERP and what actually happens on the machine. It answers the shop-floor questions: which work order is running on which machine, how many good parts were made, how long the machine stopped and why. OEE condenses that data into one figure, the product of availability, performance and quality.

The most common failure we see is OEE calculated from the wrong inputs. An ideal cycle time not defined per product pushes performance above one hundred percent, an unclear definition of planned downtime turns availability into an argument, and a reason-code list with dozens of entries ends with operators picking “other”. Before configuring anything we write these definitions down with production, maintenance and planning.

VOLSOFT builds MES and OEE on Proxus. Counts and machine states arrive automatically from the PLC; operators enter only what the machine cannot know, such as downtime reasons, scrap reasons and work-order confirmation. The OEE monitoring and alarm system we built for Doğadan’s tea packaging machines follows this approach.

What we deliver

MES and OEE Implementation

Automatic OEE calculation

Availability, performance and quality are calculated from machine signals using an ideal cycle time per product. The formula and definitions are documented, so every figure can be traced back to its source data.
Downtime tracking and reasons

Stop start and end times are captured from the machine; the reason is picked on the operator panel. Micro-stops are classified with a separate threshold, because they are what paper logs lose first.
Work-order tracking

Work orders come from the ERP, are started at the machine and close with actual quantity and time. The gap between planned and actual is visible per order.
Operator panel

The line-side panel is kept simple: active job, counter, downtime reason and scrap entry. Screens are designed to be used with gloves and finished in a few taps.
Shift and management reports

OEE by shift, line and product, downtime Pareto, scrap and MTBF/MTTR reports are produced automatically. Shift calendars, breaks and planned maintenance are reflected correctly.

How a project runs

From discovery to live, step by step

01
Definitions and scope

Planned downtime, ideal cycle time, scrap and the downtime reason tree are written down with production, maintenance and planning. The lines for the first phase are chosen.
02
Machine connectivity

Count and state signals are read from PLCs in read-only mode and modeled from the signal list. Data is validated against operator observation.
03
MES configuration

Work-order flow, operator screens, shift calendar and reports are configured. If ERP integration is in scope, work-order download and production feedback are connected here.
04
Pilot and parallel run

The system runs on a pilot line alongside the existing paper or spreadsheet tracking for a period. Differences are investigated and definitions corrected where needed.
05
Rollout and training

The validated setup moves to other lines; operators, shift supervisors and managers are trained on their own screens.

Built on Proxus

In MES and OEE projects, machine connectivity, downtime and count logic, the historian, alarms and dashboards all run on Proxus. OEE is computed from raw signals and stays on the customer’s own servers.

Proxus is the industrial data platform built by the VOLSOFT team.

OEE with Proxus ↗

Frequently asked questions

Common questions

What is an MES?

An MES (Manufacturing Execution System) is the software layer that manages and records how production actually runs on the shop floor. Work-order tracking, downtime tracking, OEE, quality records and traceability are its typical functions. In the ISA-95 model it sits below the ERP and above the automation systems.

How is OEE calculated?

OEE is availability × performance × quality. Availability is run time over planned production time, performance is actual speed against the ideal cycle time, and quality is good parts over total parts. Reliable results require a clear definition of planned downtime and an ideal cycle time per product.

What is the difference between MES and ERP?

ERP plans what to make and with which resources; MES manages and records how that plan is executed on the floor. ERP typically thinks in days or shifts, MES in minutes and machines. When integrated, work orders flow down from ERP and actual quantities and consumption flow back.

Do operators still have to enter data?

Yes, but only what the machine cannot know. Counts, states and stop times come from the PLC automatically; operators select downtime reasons, record scrap reasons and confirm work orders. Keeping manual input to that minimum is what keeps the data trustworthy.

How long does an MES implementation take?

It depends on the number of lines and machines, their connectivity and the scope of ERP integration, and is settled after a site survey. Starting with a pilot line and agreeing definitions in writing up front are the two decisions that shorten schedules most.