MES - Manufacturing Execution System
Overview
What is MES
MES (Manufacturing Execution System) is a system that manages all activities on the shop floor in real time. While ERP plans "what to produce and how much," MES tracks and controls "what is happening on the floor right now."
For example, when a production order comes from ERP, MES converts it into a work order specifying which line, which process, and which equipment to use. When a worker starts production, results (good/defect quantities) are tallied in real time, LOT numbers are automatically assigned, and the entire history from raw materials to finished goods can be traced.
VEXPLOR MES Positioning
VEXPLOR MES is an enterprise-grade MES solution supporting all manufacturing types -- from discrete (assembly, machining) to process (chemical, food, pharmaceutical). It includes ISA-95-based ERP integration, ISA-88 batch execution, and multi-protocol equipment communication (OPC-UA/Modbus/MQTT), providing a complete foundation for smart factory implementation.
Key Figures
| Item | Count | Description |
|---|---|---|
| Business Tables | 129 | All shop floor data structures: production, process, equipment, quality, LOT, batch |
| Management Screens | 110+ | Work orders, results, inspection, maintenance screens |
| Automated Workflows | 18 | Shop floor automation from work order execution to recall |
| Shop Floor POP Screens | 26 | Terminal screens across 4 categories: production, logistics, quality, equipment |
Why VEXPLOR MES
1. Real-Time Bidirectional ERP Integration
ERP production orders are automatically converted to MES work orders. When production completes in MES, results, LOT information, and defect details are automatically reflected in ERP. Manual double-entry between MES and ERP is eliminated.
2. Complete LOT Traceability
The entire history from incoming material LOTs through process-level records, material input, split/merge, to finished goods shipment is managed via LOT Genealogy. When quality issues arise, the impact scope can be immediately identified for recall response.
3. Supports Both Discrete and Process Manufacturing
Beyond work order-result management for assembly/machining lines, VEXPLOR MES supports ISA-88-based batch execution (eBR), recipe management, and PID parameter monitoring, making it directly applicable to process industries such as chemical, food, and pharmaceutical.
4. Smart Factory Equipment Communication
Four protocols -- OPC-UA, Modbus, MQTT, and EtherNet/IP -- enable direct communication with PLCs, sensors, and measuring instruments on the shop floor. Equipment alarm auto-detection, automatic downtime recording, and real-time process parameter collection are all supported.
International Standards Compliance
ISA-95 (IEC 62264)
The standard for data exchange between ERP (Level 4) and MES (Level 3). VEXPLOR MES exchanges production orders, materials, equipment, labor, and quality information with ERP in a structured manner according to this standard.
ISA-88 (IEC 61512)
The international standard for batch process control. VEXPLOR MES's batch execution module follows the Procedure - Unit Procedure - Operation - Phase hierarchy and automatically generates electronic batch records (eBR).
OEE (ISO 22400)
Overall Equipment Effectiveness (OEE = Availability x Performance x Quality Rate) is automatically calculated according to ISO 22400 KPI definitions. OEE can be monitored in real time by shift, line, and equipment.
GS1 Barcode Standard
LOT numbers, material barcodes, and finished goods labels are managed according to GS1 standards. POP screens support rapid data entry through barcode scanning.
End-to-End Manufacturing Execution Process Flow
VEXPLOR MES manages all shop floor activities from the point a production plan is received from ERP until finished goods are ready for shipment.
Meaning of Each Stage
| Stage | Description | Related Menu |
|---|---|---|
| ERP Production Order | Confirmed production plans are transmitted from ERP to MES | Integration |
| Work Order Issue | Specifies which line, which worker, and how much to produce | Production Management |
| Material Input/Scan | Scans material barcodes to confirm input | Shop Floor POP |
| Process Result Entry | Records good/defect quantities and work hours | Production Management |
| Quality Inspection | Performs SPC auto-judgment, first article inspection, final inspection | Quality Management |
| Completion/LOT Finalization | Finalizes LOT status and sends completion report to ERP | LOT Tracking |
MES Overall Data Flow
Shows how the 9 menu areas of MES are interconnected.
Menu Guide
Production Area
| Menu | Description | Detail Guide |
|---|---|---|
| Production Management | Work order issuance, production result tallying, production schedule management | From work orders to completion reports |
| Process Management | Process master, process parameters, routing, process BOM, recipes | Process design and standard management |
| LOT Tracking | LOT genealogy, split/merge, expiry dates, recall response | Tracing from raw materials to finished goods |
| WIP Management | WIP tracking, buffer zones, packaging, inter-process movement | WIP flow between processes |
Equipment/Maintenance Area
| Menu | Description | Detail Guide |
|---|---|---|
| Equipment Management | Equipment master, molds/tools, OEE, downtime management | Equipment status and efficiency |
| Maintenance Management | Preventive maintenance, maintenance work orders, equipment inspection, spare parts | Equipment life extension and failure prevention |
Quality Area
| Menu | Description | Detail Guide |
|---|---|---|
| Quality Management | Defect management, SPC, first/last article inspection, CAPA | Process quality assurance |
Shop Floor/Analysis Area
| Menu | Description | Detail Guide |
|---|---|---|
| Shop Floor POP | Work status board, process result entry, quick defect entry, barcode scanning | Shop floor terminal user guide |
| Shift/Worker Management | Shift definitions, shift calendar, handover, worker skills/assignments | Shift operations and workforce management |
| Status/Analysis | OEE trends, defect Pareto, equipment utilization, KPI | Production metrics monitoring |
Special/Integration Area
| Menu | Description | Detail Guide |
|---|---|---|
| Batch Execution | ISA-88 batch, batch records, material charges, golden batch | Process manufacturing batch management |
| Safety/Environment | Safety incidents, environmental monitoring, energy consumption | Shop floor safety and environmental management |
| Integration | MES-ERP mapping, equipment communication, outsource processes | External system integration |
18 Automated Workflows
VEXPLOR MES automates repetitive shop floor tasks through 18 workflows.
Production Execution Workflows
| Workflow | Description |
|---|---|
| WF1: Work Order Execution | Work order issue - LOT auto-generation - material scan - result entry - quality inspection - ERP sync |
| WF6: Material Consumption Tracking | Auto-record material consumption vs. BOM - ERP inventory sync |
| WF8: Final Inspection/Shipment | Finished goods final inspection - warehouse receipt upon passing |
| WF11: OEE Auto-Calculation | Auto-calculate Availability x Performance x Quality Rate at shift end |
| WF15: Daily Production Close | Daily results tally - auto-generate reports |
Quality Workflows
| Workflow | Description |
|---|---|
| WF2: Quality Inspection | Measuring instrument validation - SPC auto-judgment - CAPA auto-generation on anomaly |
| WF7: CAPA | Auto-register corrective/preventive action on 3+ repeat defects |
| WF12: Rework | Non-conforming LOT - rework approval - rework execution - re-inspection |
| WF13: First Article Inspection | Parallel dimension/function/appearance inspection - approval - mass production authorization |
Equipment/Maintenance Workflows
| Workflow | Description |
|---|---|
| WF3: Equipment Breakdown Response | Breakdown alert - parts check - maintenance order - repair - MTBF/MTTR calculation |
| WF5: Preventive Maintenance | Cycle-based maintenance plan - parts tracking - inspection execution |
| WF9: Andon Escalation | Andon event trigger - staged alert escalation |
| WF18: Alarm Response | Alarm severity-based branching - emergency stop/action/escalation |
Shift/Shop Floor Workflows
| Workflow | Description |
|---|---|
| WF4: Shift Handover | Safety check - auto-generate shift report - carry over pending tasks |
| WF10: Process Change Notification | ECO (Engineering Change Order) reflection - notify related departments |
| WF14: Line Changeover | SMED-based line changeover - time recording - first article inspection linkage |
Special Workflows
| Workflow | Description |
|---|---|
| WF16: Batch Execution | ISA-88 recipe load - material charge - phase execution - eBR generation |
| WF17: Recall/Recovery | LOT back-trace - parallel processing (customer notification/inventory hold/shipment hold) - root cause analysis |
MES and Other Solution Connections
| Linked Solution | Data Exchanged |
|---|---|
| ERP | Receive production orders, send completion reports/results/LOT, defect sync, inventory reflection |
| QMS | Process inspection requests, receive inspection results, CAPA linkage on non-conformance |
| WMS | Finished goods receipt, material issue requests, inventory sync |
| SCM | Receive raw material incoming LOTs, outsource processing management |