We understand the language of the industry. We understand digital technologies. We bridge the gap between your needs and the paradigm shift, digitalization solutions can bring to your business.

Data Connectivity
Data Management
Data Operations
Data Analytics

HQ – Digital Business

Location
Consyst Digital Inc.
16192 Coastal Hwy Lewes,
Sussex, Delaware – United States
Phone
+1 832 548 5863

Center of Excellence

Location
Center of Excellence
CONSYST Digital Industries Pvt Ltd.,
SmartSpace.Kochi, Biznes Avenue,
Edayapuram PO,
Ernakulam 683101,
Kerala – INDIA
Phone
+91 484 262 8448
Email
solutions@consyst.biz

Are you interested in our Industrial Automation Solutions?

Explore
Consyst

Manufacturing Execution Systems (MES)

Data OperationsStreamline Manufacturing process with MES solution.

Gain Real-time insights and optimise the operations for Discrete Manufacturing Industry

Our Manufacturing Execution Systems (MES) is built on Ignition platform designed to collect and analyze data from machines and production lines in discrete manufacturing, presenting it in an intuitive and user-friendly way. By implementing our solution, operators can achieve greater predictability in their tasks, while managers gain the insights needed to make well-informed decisions. This leads to faster and more effective production processes. Our MES system offers key advantages such as detailed analytics, identification of underperforming processes, resolution of root causes, support for quality control and compliance, reduction in product defects, improved internal communication, and minimized downtime. These capabilities enhance overall plant performance and ensure consistent quality in manufacturing.

Manufacturing Execution System (MES) |

MES Built on Ignition Platform

Challenges Across Organizational Levels

Production Planning & Control
  • Limited data accuracy due to disconnected systems
  • High reliance on manual tracking processes
  • Poor interdepartmental coordination (quality/maintenance)
  • Difficulty identifying bottlenecks, slowing production
  • Lack of real-time production line monitoring
  • Challenges in dynamic schedule adjustments and changeovers
  • Equipment breakdowns causing delays and backlogs
Maintenance Manager
  • Unplanned downtimes due to limited predictive maintenance.
  • Difficulties in prioritizing maintenance tasks.
  • Shortage of replacement parts and resources.
  • Difficulty in analyzing maintenance data effectively.
  • Inconsistent maintenance schedules across equipment.
  • Lack of real-time / immediate information on equipment failure
Quality Manager
  • Maintaining quality consistency across shifts.
  • Identifying root causes / tracing back source of defects efficiently.
  • Limited insights into real-time production quality.
  • Struggles meeting regulatory compliance.
  • With large-scale production, a manual quality check is limited to random sampling of about 50 units, leaving a risk that other defective products may pass through unchecked.
Operational Level
  • Lack of knowledge about the machine operation and subsequent processes.
  • Limited access to real-time insights on production progress.
  • Delays in obtaining approvals from higher management can hinder progress and stall subsequent processes.
  • Constant changes in equipment or recipes can lead to confusion and decreased efficiency.

Are you facing any of these challenges in your manufacturing process? Contact us to discover a smarter, more efficient solution tailored to your needs.

Get in Touch

ServicesMES Software Modules

Our MES modules are designed to improve manufacturing efficiency by providing real-time insights, ensuring process consistency, and helping you make informed decisions for better operational performance. Below are the key modules that drive these improvements

Statistical Process Control (SPC)

Ensure consistent collection of SPC data mitigating late/missing sample data affecting quality, utilizing advanced SPC control charts

Workorders and Changeovers

Enhance production efficiency and data integrity by managing master and sub-recipes, ensuring security, tracking changes, and monitoring process variations.

Instrument Integration Module

Capture raw textual data from instrument devices via serial devices (including weighing scales, measurement gauges, barcode readers etc.), text files, and more.

Interface for ERP/ Third Party Applications

Robust integration capabilities, ensuring compatibility with ERP systems and other third-party software applications.

Quality Operations
Module

Streamline and elevate quality management processes, ensuring that products meet or exceed industry and customer standards.

Overall Equipment Effectiveness (OEE)

Maximize operational profitability by effectively measuring OEE and downtime across entire production line.

Resource Management and Access Control

Efficient resource allocation and access control are facilitated through real-time insights, secure user authentication, role-based permissions, and comprehensive audit trails.

Analytics and Reporting
Module

Get actionable insights with real-time data visualization, custom report generation, historical data analysis, performance KPI tracking, and mobile accessibility for informed decision-making.

SKU Track and
Trace

Streamline product tracking and tracing, monitor product journeys, access comprehensive genealogy data, establish uniform operator interfaces, and serialize items for meticulous record-keeping.

Benefits of MES

The MES system brings significant improvements to manufacturing processes. Below are the key benefits that organizations can expect from implementing our system, driving enhanced efficiency, quality, and operational performance.

Enhanced Traceability
  • Track each production step in real-time
  • Ensure product genealogy
  • Compliance with industry standards.
  • Simplify audits and recalls.
Overall Equipment Effectiveness
  • Monitor equipment in real-time.
  • Pinpoint downtime causes fast.
  • Maximize equipment use with proactive maintenance.
Improved quality
  • Automated or manual defect reporting.
  • Automate quality checks for rejects and rework.
  • Ensure high-quality standards in production.
Production Efficiency
  • Optimize workflows and resources.
  • Cut cycle times.
  • Eliminate bottlenecks.
Greater visibility
  • Attain live production data.
  • Enables quick decision-making.
  • Tracks from raw material to finished goods

Get actionable insights and improve your production.

Looking to enhance efficiency, quality, and traceability in your discrete manufacturing process? Contact us to learn how our MES solution can help streamline your operations and improve productivity.

Contact Us

Case StudiesExplore Our Latest Case Studies

Revolutionizing Maintenance Condition based Maintenance (CbM)
Revolutionizing Maintenance: Condition based Maintenance (CbM) and Preventive Maintenance Planner for 1800+ Motors in Petrochemical Refinery
The power & utilities department lacked an effective maintenance tr
Read More
Wireline Equipment Monitoring Devicene Control
Product Design and Development of a Wireline Equipment Monitoring Device
The primary application of wireline equipment in oilfields is for well
Read More
Kaplan Turbine Control
Streamlining Kaplan Turbine Control: A Case Study on Design
Turbine controllers are crucial components in modern turbomachinery, pr
Read More