Close the gap between
your floor and your business.
MES and enterprise integration where operational technology meets information technology — bridging both sides where most implementations fail.
ERP thinks the order is complete when someone enters it manually. The floor finished two hours ago.
- —CSV exports pasted into spreadsheets
- —Batch records filled in by hand
- —Production schedules built in Excel
Floor data flows to business systems automatically. No manual entry. No reconciliation.
- Production data in ERP in real time
- Electronic batch records from system data
- Work orders dispatched from ERP to floor
Not another dashboard,
engineered integration.
Your ERP thinks an order is complete when someone enters it manually. Your quality team is exporting CSV files from the historian and pasting them into spreadsheets to generate a Certificate of Analysis. Your planning team is building production schedules in Excel because the ERP doesn't know what the floor is actually running.
MES and enterprise integration is where operational technology meets information technology — and where most implementations fail. Most automation firms don't understand ERP. Most IT consultants don't understand PLC data. We work across both.
We bridge both sides: PLC tag structures and historian data on the plant floor, and work order models and material transactions in SAP, Oracle, or your business system.
Six integration capabilities,
one connected operation.
Manufacturing Execution System deployment for production tracking, work order management, material genealogy, quality management, and performance analysis. Not every plant needs a full commercial MES platform — some need three specific functions and those can be built on Ignition or a lightweight module without the six-figure license and 18-month timeline. We help you figure out which category you're in before you commit.
Bi-directional data exchange between plant-floor systems and enterprise resource planning platforms. Work orders pushed from ERP to the floor. Production counts, material consumption, quality results, and labor data pushed back up. No manual entry. We build integrations with SAP (RFC, BAPI, IDoc, OData), Oracle, Microsoft Dynamics, Epicor, and other ERP platforms — with message queuing, error handling, retry logic, and transaction logging.
Bridging process historians to MES and business systems. Contextualizing time-series process data with production context — batch ID, product code, lot number, operator shift — so the data is useful for quality, compliance, and operational analysis, not just raw tag trends. Historian architectures that serve both real-time operations and long-term business needs.
Electronic batch records that capture every process parameter, material addition, operator action, and quality checkpoint automatically — without operators filling in paper forms. For regulated environments: 21 CFR Part 11 compliant electronic records with audit trails, electronic signatures, time-stamped entries, and controlled access. Batch records generated from system data, not manual input — because manual input is where errors and compliance findings come from.
Lot tracking from raw material receipt through production, packaging, and shipment. Forward and reverse traceability so you can answer 'what products did this raw material go into?' and 'what raw materials went into this product?' in minutes, not hours. Barcode and RFID integration for material identification at receiving, staging, production, and shipping.
Automated Overall Equipment Effectiveness tracking from PLC and SCADA data — not operator-entered downtime reasons on a touchscreen that gets ignored when the line is busy. Availability, performance, and quality components calculated from system data with drill-down capability. Downtime Pareto analysis, rate loss identification, and quality reject trending designed for continuous improvement programs.
Every operation
with a data gap to close.
If your floor and your business systems don't share data automatically — there's a gap we can close.
Electronic batch records, material genealogy, deviation tracking, and compliance reporting. MES as the backbone of GMP operations.
Production tracking, allergen management, lot traceability, and regulatory reporting. ERP integration for inventory accuracy and demand planning.
Work order management, production counting, labor tracking, and quality data capture. OEE and downtime tracking for continuous improvement.
Batch tracking, formula management, material consumption, and yield analysis. Integration between batch control systems and business planning.
Multi-customer production tracking, customer-specific quality requirements, and reporting. Systems that handle product-specific configurations without custom code for each customer.
Connecting planning systems to floor-level execution. Work order dispatch, sequencing logic, and schedule visualization that gives operators and supervisors visibility into what's running, what's next, and what changed.
From data gaps
to connected systems.
Define the gaps.
We map your current data flows — what information exists on the floor, what the business systems need, and where the gaps are. Manual entry points, missing traceability, and disconnected systems are identified before any architecture is proposed. The scope is driven by your actual pain points, not a vendor's feature list.
Design the architecture.
ISA-95 data model design, integration pattern selection, and platform recommendation. We determine whether the answer is a commercial MES, a focused Ignition application, or a lightweight custom solution — and document the architecture so your IT and OT teams both understand what's being built.
Build the integration.
MES configuration or custom development, ERP connectors, historian contextualization, and electronic batch record design. Integration built with message queuing, error handling, and transaction logging so you know exactly what data moved and when.
Test and validate.
End-to-end testing of every data flow, batch record validation against defined acceptance criteria, and ERP transaction verification. For GMP environments: IQ/OQ/PQ protocols with documented evidence. Parallel operation with existing systems until confidence is established.
Deploy and train.
Production deployment, operator and supervisor training, and IT team handoff. We design interfaces and workflows around how your team actually operates — input screens are fast, mobile interfaces work with gloves, and data entry is minimized because the system captures what it can automatically.
Platforms and technologies.
The right integration pattern depends on your systems, data volume, latency requirements, and IT policies.
OT and IT,
under one roof.
We start with the problem, not the platform.
Most MES vendors start with their platform and configure your operation into it. We start with your workflows, your data gaps, and your integration requirements — then determine whether the answer is a commercial MES, a focused Ignition application, or a lightweight custom solution. Sometimes the honest answer is that you don't need an MES at all. We'll tell you that.
We speak both languages.
MES sits at the intersection of OT and IT. The implementation team needs to understand PLC tag structures and SCADA architectures on one side — and ERP work order schemas and business process workflows on the other. Most MES implementations fail because the team only understands one side. We work across both because our automation and software divisions are the same company.
We build for adoption.
The most technically perfect MES is worthless if the operators won't use it. We design interfaces and workflows around how your team actually operates. Input screens are fast. Mobile interfaces work with gloves. Data entry is minimized because the system captures what it can from PLCs and historians automatically. The system earns adoption by making people's jobs easier, not harder.
Integration reliability by design.
Every integration is built with message queuing, error handling, retry logic, and transaction logging. A failed API call at 2 AM gets retried and logged — not discovered three days later when someone notices missing production data. You know exactly what data moved, when it moved, and what failed.
Straight answers.
Maybe, maybe not. If you need full ISA-95 functionality across multiple plants with hundreds of users, a commercial MES makes sense. If you need three specific capabilities — say, batch records, OEE tracking, and material traceability — we can often build exactly what you need on Ignition or a custom platform at a fraction of the cost and timeline. We'll give you an honest recommendation.
A focused implementation covering 2–3 core functions typically takes 3–6 months. A full enterprise MES deployment across multiple lines or plants takes 6–18 months depending on scope, number of integrations, and validation requirements. The biggest variable is usually organizational readiness — defining workflows, business rules, and master data — not the technical implementation.
Yes. We work with OSIsoft PI, Ignition Tag Historian, FactoryTalk Historian, AVEVA Historian, and others. If your historian is already collecting the process data, we build the contextualization and integration layers on top of it rather than replacing it.
Integration between plant-floor systems and enterprise systems crosses the IT/OT boundary. We design architectures with appropriate network segmentation, DMZ placement, and data flow controls. We work with your IT team to meet their security policies while ensuring the integration performs reliably.
SCADA monitors and controls the physical process in real-time — it's the operator's tool. MES manages production execution — work orders, material tracking, batch records, quality, and performance analytics. They serve different purposes but share data. In our implementations, SCADA provides the real-time process data that MES contextualizes with production information. They're complementary layers, not competing systems.
Yes. We design electronic batch records that capture process data automatically from PLCs and historians, guide operators through manual steps with enforced sequences, and generate completed batch records with full traceability. The transition from paper is managed carefully — running parallel systems until confidence is established.
Ready to connect your floor to your business?
Whether it's an MES implementation, an ERP integration, a batch record system, or better production visibility — tell us where the gaps are.