MES Integration & Legacy Modernization
Our methodology for replacing fragmented legacy systems with one integrated production platform.
This case study is a methodology demonstration using an illustrative company. It showcases our approach and capabilities but does not represent an actual client engagement.
25-40%
Projected efficiency improvement
Significant
Projected cost savings
50-70%
Projected reduction in manual entry
Minutes
Projected deviation detection
The Challenge
Manufacturing companies often operate with multiple non-integrated systems: an outdated MES, a separate quality registration system, and manual reports for management. Data must be manually retyped between systems, errors are inevitable, and real-time production insight is absent.
Our Approach
Our methodology provides for a phased migration approach where the new platform is rolled out line by line without production interruptions. Edge computing on the shop floor enables capture of machine data that was previously unreachable.
Process Analysis & System Audit
4-6 weeksDetailed mapping of all production processes, data flows, and integration points with existing systems.
Unified Platform Architecture
3-5 weeksDesign of the integrated platform with OPC-UA integration, real-time dashboards, and mobile work orders.
Phased Rollout per Production Line
20-30 weeksLine-by-line implementation with parallel operation to minimize risks and train operators.
Optimization & Predictive Analytics
6-10 weeksMachine learning models for predictive maintenance and production optimization based on historical data.
Projected Outcomes
Based on our methodology, we project elimination of manual data transfer, significant reduction in quality deviation detection time, and real-time production insight for management. Cost savings are primarily expected through efficiency improvement and waste reduction. Exact results depend on the complexity of the production environment and the baseline situation.
“Our manufacturing methodology focuses on delivering real-time production insight without production interruptions, through a phased implementation approach that minimizes risks and gradually onboards operators.”
Technologies Used
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