Video · Downtime management
A stoppage, from its first second on the machine to the Pareto report.
The stop is captured from the PLC, the reason code is selected on screen and it appears in the Pareto report within the same minute.
Manufacturing execution system (MES)
İldiko MES
Combines data from machines, operators and the ERP into a single real-time picture. OEE and downtime are live; confirmations and quality results reach the ERP without delay.
Live OEE, availability, performance and quality for every line and every shift
Two-way ERP integration: orders come down, confirmations and results are written back
Direct PLC and SCADA connectivity: OPC UA, Siemens S7, Modbus, Allen-Bradley
Unlimited users and screens on a single license
Why İldiko MES
The shop floor, the ERP and management look at the same numbers
Makes losses visible
OEE is calculated live for every line, and downtime reasons are ranked in a Pareto chart. How much was lost on which shift and which machine is no longer up for debate.
Connects the ERP and the shop floor
Production orders, recipes and inspection plans come down from the ERP; confirmations, goods issues and quality results are written back. Operators never see an ERP screen, and the ERP gets shop floor data without delay.
Works with your existing automation
Connects directly to PLCs over OPC UA, Siemens S7, Modbus and Allen-Bradley, or reads from your existing SCADA. No new hardware required.
Features
Production, quality and warehouse in one system
OEE, availability, performance and quality are calculated live for every line. The plant dashboard shows at a glance which machine is running, which is in planned downtime and which has minor stops.
- Active production order, remaining quantity and remaining pallets
- Shift target and actual side by side
- Machine status on a color-coded timeline
The stop signal comes from automation; the operator selects the reason code on screen. Planned and unplanned downtime are tracked separately, and Pareto analysis highlights the reasons that cost the most time.
- Category and reason code hierarchy
- Breakdown by shift and line
- Technical, process and autonomous maintenance stops kept apart
Periodic analysis splits the OEE trend day by day into quality, performance and downtime loss, and compares it with the previous period. OEE, downtime and production reports are generated instantly for any scope and date range.
- Plant, line and shift scope
- Comparison with the previous period
- Runtime and downtime breakdown for the last 30 days
A tree view shows which production orders, which machines and which finished-goods pallets a raw material batch went into. In reverse, every component and operator behind a pallet is listed.
- Forward and backward traceability
- Inventory, handling unit, batch and material nodes
- Hundreds of nodes in seconds
The operator sees on screen how much of each material to weigh. The scale reading goes straight into the system, and out-of-tolerance weighings are rejected. Every weighing is recorded with handling unit, batch and operator.
- Smart scale integration
- Automatic weighing report per production order
- Works one-to-one with the ERP recipe
Videos
Watch İldiko MES at work
Video · ERP integration
A process order, from the ERP to the shop floor and back.
The order arrives in İldiko MES, runs on the line, and production confirmations are written back to the ERP automatically.
More modules
The rest of the shop floor in the same system
Quality management
Lab samples and results are entered on a tablet; shop floor inspectors see which inspection is due on which line. Results are written to the inspection lot in the ERP.
Machine data collection
PLC and DCS connectivity over OPC UA, Modbus, Siemens S7, Allen-Bradley and other protocols. It reads from your existing SCADA, or İldiko takes over the SCADA layer.
Component consumption and material requests
Consumption is recorded by the machine or the operator and posted to the ERP as a confirmation. Operators request line-side material on screen, and the request opens as a warehouse task.
Maintenance and breakdowns
Breakdown notifications are opened on screen and passed to the ERP maintenance module; the maintenance team records the work and closure. Breakdown time flows into OEE automatically.
Safety information
Safety instructions linked to the production order and material safety data are shown on the operator’s screen together with the order.
Label and printer management
Product, carton and pallet labels are generated from production order data and sent directly to printers on the line. Regulatory formats such as UDI are supported.
ERP integration
Two-way, real-time ERP integration
Master data and orders come down from the ERP; confirmations, goods issues, quality results and notifications are written back. We have ready-made connectors for SAP; with other ERP systems the same flows are built over standard interfaces.
Production Planning and execution
- Production and process orders
- Material master, bill of materials, routing
- Confirmation, goods issue and scrap posting
Quality Inspection and decision
- Inspection plans and inspection lots
- Lab and shop floor result entry
- Sample records and usage decision
Maintenance Breakdowns and maintenance
- Breakdown notification from the shop floor
- Maintenance order and closure details
- Breakdown time matched with OEE
Warehouse Stock and handling units
- Handling units and stock movements
- Material requests from the line, warehouse tasks
- Putaway of produced pallets
Machine and device integration
Connects to every signal source on the shop floor
Connects directly to PLCs with industry-standard drivers and manages scales, barcode scanners and label printers on the line. It reads data from your existing SCADA, or takes over that layer itself.
- OPC UA
- Siemens S7
- Modbus TCP
- Allen-Bradley
- Existing SCADA
- Smart scale
- Barcode scanner
- Label printer
Operational visibility
The last 30 days, every line, every shift
The operations report shows runtime, planned and unplanned downtime day by day. Hover over any line’s shift timeline to see the downtime reason, duration and comment.
On every device, for every role
- Line-side panel Operators see the production order, target, downtime and quality entry on one screen.
- Tablet The quality team enters samples, measurements and results on the spot, in the lab and on the shop floor.
- Laptop and office Managers follow the plant dashboard, periodic analysis and reports.
Success story · Cosmetics
Seamless traceability from recipe to pallet
One of the leading manufacturers in the cosmetics industry chose İldiko MES to digitize its manual recipe preparation and weighing processes and to get traceability fully integrated with ERP warehouse management.
30%faster weighing processes
Zerooperational weighing errors
Challenges
- Weighing left to operator judgment created a quality risk.
- Tracking was per batch only, with no handling unit detail.
- There was no live data flow between the warehouse and the shop floor; stock transfers were manual.
Results
- Smart scales prevent off-recipe weights.
- Traceability for every handling unit.
- Production and warehouse movements are synchronized bin by bin with the ERP warehouse and quality modules.
- OEE tracking became real-time.
Chemicals and cosmetics
A ready package for recipe-based production
Process order management, recipe-driven weighing with scale integration, tolerance checks, batch traceability per handling unit and bin-level synchronization with ERP warehouse management come standard in this package.
- Built on Ignition. A platform proven in industry, with a tag-based data model, SQL and reporting built in.
- Scalable. From a single line to multiple plants; new lines or sites are added without disrupting what is in place.
- Customizable. Screens, workflows and reports are designed around your plant’s needs.
Frequently asked questions
Your questions, answered
Which ERP systems does it work with?
For SAP we have ready-made connectors for the production, quality, maintenance and warehouse modules (PP, QM, PM, EWM). With other ERP systems the same flows are built over web services or database interfaces.
How does it connect to our existing PLC and SCADA infrastructure?
It connects directly to PLCs with OPC UA, Siemens S7, Modbus and Allen-Bradley drivers. If the plant has a SCADA system, it reads the data from there over OPC; if not, İldiko takes over the SCADA layer itself.
How is it licensed?
A single server-based license. Users and screens are unlimited; adding a new line or operator requires no additional license.
Where does it run, and how is it accessed?
It runs on a server inside your plant. Line-side panels, tablets and office computers access it from a browser; there is no client installation.
Next step: see İldiko MES on your own line
Contact us for a demo tailored to your plant. In the first meeting we review your current ERP and automation setup together.