The execution layer between machines and the office
ControlMES records what is happening on the shop floor by machine, lot and order, and delivers it to the people who make decisions.
Where ControlMES fits
ControlMES delivers See and Link, and part of Predict.
Predict
Know what is about to happen, in time to act and plan ahead.
Link
Know how far you are off plan, and which orders and customers are affected.
See
Capture run time, downtime and scrap at the source.
Foundation
Standardized master data: item codes, process steps, production standards.
ERP and ControlMES
| System | Answers | Used for |
|---|---|---|
| Accounting, ERP | How much did we lose last month? | Record-keeping |
| Reporting, BI | Where did we lose last week? | Lessons learned |
| ControlMES | Where are we losing right now, and which customer is affected? | Acting in time |
ERP
- Serves the office
- Measured in money
- Cadence: monthly, quarterly
- Asks: how much profit?
- Users: accounting, purchasing, management
ControlMES
- Serves the shop floor
- Measured in hours, pieces, lots
- Cadence: by the second, by the shift
- Asks: what is happening?
- Users: supervisors, planning, warehouse, QC, sales
ControlMES runs alongside your existing ERP. Factories without an ERP can start with ControlMES; standardized production data makes a later ERP rollout faster.
No extra work for operators
Data is captured while people do their normal work, from three sources:
From machines
Counters, scales, PLCs and run/stop signals are recorded automatically.
From existing tasks
Barcode scans replace paper logs at goods receipt, handover and packing.
Picked on screen
What a machine cannot record, such as the reason for a stop, the operator picks from a list. A few taps and done.
Connected machines, accurate real-time data
ControlMES takes data straight from the machines: output, cycle time, run time and downtime. The numbers are accurate, updated in real time, and don't depend on handwritten logs.
- Newer machines: data read from the machine controller.
- Older machines and imported machines without documentation: signals captured through sensors.
- Safe for the machine: no changes to the machine's control system.
A screen for every role
Every role gets its own screen, all fed by the same real-time data. Operators, supervisors, sales and management see the same numbers.
At the machine
Tablet, Vietnamese interface, large buttons, touch operation.
Supervisor
Status of every line and running work order on one screen.
Management
Which lines are running and which orders are at risk, on one screen.
Modules
Deploy modules one at a time or together, as your factory needs.
| Module | What it does | Status |
|---|---|---|
| Master data | One trusted source for item codes, process steps, standards, machines, shifts | Live |
| Planning & scheduling | Plans based on real capacity, re-planned quickly when something goes wrong | Live |
| Production tracking | See how the floor is running now, without waiting for the end-of-shift report | Live |
| Inventory & material flow | Stock accurate to the lot, the roll, the kilogram | Live |
| Quality management | Incoming, in-process and final inspection; defects traced to lot, machine, shift | Live |
| Machine connectivity | Data taken from machines, not from handwritten logs | Live |
| Traceability | Trace a lot from raw material to customer in minutes | Live |
| Management reporting | The whole plant and its bottlenecks on one screen | Live |
| Maintenance | From fixing breakdowns to planned maintenance | Live |
| Workforce | Staff allocation by shift and by skill | On the roadmap |
AI in ControlMES
AI is only as accurate as the data behind it. ControlMES uses AI to standardize data, analyze machine data, and capture the know-how of the people on the floor.
Data standardization Live
AI helps standardize item codes, process steps and production standards, cutting the time to 2–4 weeks.
Machine data analysis Live
AI analyzes the data collected from machines (downtime, cycle time, scrap) and pinpoints exactly where performance is held back.
Less dependence on key technicians Live
How technicians set up machines and fix problems is logged. AI analyzes it and turns it into documentation, so the know-how stays in the factory when people move on.
Ask in Vietnamese On the roadmap
Query factory data with everyday questions in Vietnamese, no report building needed.
Technology and data
Web-based
Works on computers and tablets, with nothing to install.
Flexible deployment
Cloud or on-premises server, as the factory prefers.
IoT at the machine
Machine data captured through IoT gateways and sensors, using common industrial protocols.
Barcode, QR, RFID
Scan at receiving, issuing and handover; RFID where automatic tracking is needed.
Integration
Connects to your ERP and accounting software via API; accepts Excel files where no integration exists yet.
Security and audit trail
Role- and plant-based access; a log records who did what, and when.
Continuous updates
New features ship in short iterations, with no waiting for major version upgrades.
Your data
Your data belongs to your factory, standardized and ready for analytics and AI.
Contact
A 1-day on-site assessment, free of charge, to see how well ControlMES fits your factory.