Solution — Manufacturing & MES
Your factory's entire heartbeat on one real-time screen
From raw material receipt to finished goods dispatch: a Manufacturing Execution System (MES) engineered around your exact machine routing, line capacities, and scrap codes.
Custom manufacturing software (MES) captures every shop-floor event — operational routes, operator performance, machine telemetry, scrap root causes, and work order progress — in real-time sub-second sync. Unlike rigid ERP packages that treat manufacturing as a static data-entry afterthought, KodDelta builds systems that mirror your exact shop floor physics. The first live production terminal is operational within 2 to 4 weeks.
The 4 Critical Failures of Standard Factory Software
Most mid-sized manufacturers struggle with disconnects between planning and reality on the factory floor:
- Delayed Production Visibility: Work order completions and scrap counts are compiled on paper and entered into accounting software days later. Management only discovers bottlenecks after delivery dates have passed.
- Inaccurate Unit Costing & Scrap Leakage: Standard ERP packages calculate costs using theoretical estimates rather than actual operator hours, machine electricity, and lot-specific raw material scrap variances.
- Traceability Blindspots: When a customer reports a quality defect, tracing which raw material batch, machine operator, or subcontractor contributed to the defect takes days of manual paper searching.
- Shop-Floor Operator Resistance: Complex, text-heavy desktop screens fail on the factory floor because operators cannot afford 5 minutes per operation to type data.
End-to-End Manufacturing Modules
We deliver an integrated suite of factory-floor modules customized to your production workflow:
Digital Work Orders & Routing
Define sequential multi-station routes (Laser Cutting → CNC Bending → Robotic Welding → Powder Coating → Assembly). Auto-dispatch work orders as predecessors finish.
Shop Floor Touch Terminals
Industrial kiosk screens and barcode scanners designed for operators wearing work gloves. Start operation, report scrap quantity with predefined reason codes, and log downtime in 15 seconds.
Real-Time OEE & Downtime Analytics
Continuous calculation of Overall Equipment Effectiveness: Availability × Performance × Quality. Real-time visual alerts when a machine experiences unplanned stoppages.
Dynamic BOM & Recipe Management
Multi-tiered Bills of Materials with variable scrap percentages, dimensional cutting optimization, alternative raw material recipes, and automatic inventory reserve locks.
Full Lot & Batch Traceability
Unbroken digital lineage connecting supplier raw material certificate → internal furnace/production lot → intermediate sub-assembly → finished product serial number → dispatch invoice.
Subcontractor & External Process Tracking
Track materials dispatched to external plating, galvanizing, or heat-treatment vendors with return inspection workflows, yield loss metrics, and automatic service billing.
The Real-Time OEE Calculation Engine
Our MES provides continuous, actionable insights into production efficiency using standard international formulas:
| OEE Component | Measurement Metric | How KodDelta Automates It |
|---|---|---|
| Availability (%) | Operating Time / Planned Production Time | Touchscreen/PLC stop reason tagging (tool change, breakdown, setup) |
| Performance (%) | (Total Count × Ideal Cycle Time) / Operating Time | Real-time piece counting vs. standard engineering cycle tolerances |
| Quality (%) | Good Count / Total Count Produced | Instant scrap recording categorized by defect taxonomy and rework routes |
Why Packaged Software Fails on the Factory Floor
| Capability | Standard Accounting / ERP Package | KodDelta Custom MES |
|---|---|---|
| Shop Floor Usability | Complex accounting menus | Rugged 3-tap tablet kiosk interface with barcode scanning |
| Scrap & Defect Logic | Single generic loss field | Categorized root-cause scrap trees + rework loop routing |
| Machine & PLC Integration | Not supported or costly proprietary add-on | Direct Modbus, OPC-UA, MQTT, and IoT sensor telemetry ready |
| Actual vs. Standard Cost | Theoretical estimates only | Exact actual labor, machine time, and material scrap costing |
Phased Implementation Plan
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Route & Master Data Modeling (Week 1–2)
We document your product families, standard cycle times, machine capacity constraints, and quality inspection criteria into a unified schema.
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Shop Floor Kiosk Deployment (Week 2–3)
We deploy rugged touch terminals and wireless barcode scanners on your pilot production line and train machine operators on-site.
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Live Production Validation (Week 3–4)
Live work order dispatching begins on the pilot line; managers track real-time bottleneck shifts on executive TV dashboards.
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Full Plant Rollout & ERP Synchronization
Rollout across all production cells with automated bi-directional data flow to existing accounting software for inventory and billing synchronization.
Frequently Asked Questions
Can this system integrate with our CNC machines, PLCs, or sensors?
Yes. We support standard industrial communication protocols including MQTT, OPC-UA, Modbus TCP, and REST gateways to capture cycle counts and machine alarms directly from equipment.
How are rework and re-machining processes handled?
If an inspector rejects a part at quality control, the system can instantly generate a branched 'Rework Work Order' with custom routing, separate labor logging, and adjusted scrap costing.
Is internet connectivity required on the factory floor?
No. The local shop-floor kiosks can be configured on an on-premise local area network (LAN) with local fallback caching, ensuring production never halts during external internet outages.
Transform your factory operations with real-time clarity.
Book a 30-minute discovery call with our manufacturing systems architects to map your shop-floor digital strategy.