MES Systems.
Manufacturing execution, SCADA visualization and production data integration structured to the ISA-95 model.
- ISA-95
- ISA-18.2
- OPC UA / IEC 62541
Service scope
ISA-95 Architecture & Data Modelling
A plant model that scales from one line to full rollout and makes ERP integration a mapping exercise.
- Level 0-4 model applied to plant data flow
- Clear boundary between control and MES layers
- Equipment hierarchy: site, area, line, cell
- Standardized naming across the plant model
- ERP integration becomes mapping, not rework
- Scalable from one line to full plant rollout
MES Application Design & Development
Ignition-based traceability, work instruction and error-proofing applications.
- Ignition-based MES application development
- Traceability, genealogy and part-level history
- Work instruction and operator guidance screens
- Python scripting for workflow and business logic
- Error-proofing and interlocked process steps
- Live production support post-deployment
SCADA Visualization
Supervisory screens, andon displays and role-based access across the plant.
- Ignition Vision and Perspective supervisory screens
- Real-time line and area production monitoring
- Browser and mobile access via Perspective
- Role-based access control and audit trail
- Consistent screen standards across the plant
- Andon and status displays for the shop floor
SQL Data & Historian Integration
Production data captured, retained and made queryable without gaps.
- SQL schema design for production data
- Tag historian configuration and retention strategy
- Store-and-forward for network interruptions
- Query and reporting layer for downstream users
- Integration with existing plant databases
- Data validation and integrity checks
Production Reporting & OEE
Availability, performance and quality reported to standard OEE definitions.
- Availability, performance and quality to standard OEE
- Downtime reason capture and Pareto analysis
- Shift, line and part-level production reporting
- Scrap and rework tracking against production
- Automated report generation and distribution
- Historical trending for continuous improvement
Recipe & Parameter Management
Controlled parameter download, version history and faster changeover.
- Central recipe store for multi-product lines
- Controlled parameter download to the PLC
- Version control and full change audit trail
- Role-based approval before recipe release
- Recipe comparison and rollback capability
- Changeover time reduction through recipe-driven setup
Alarm Management
ISA-18.2 rationalization that removes nuisance alarms and guides operator response.
- ISA-18.2 alarm lifecycle methodology
- Alarm rationalization to remove nuisance alarms
- Priority, class and shelving configuration
- Alarm history, notification and routing
- Top-10 bad-actor alarm reporting
- Operator response guidance per alarm
Remote Support & Optimization
Live remote engineering after go-live: tuning, change requests and health checks.
- Live remote debugging of MES and SCADA issues
- Performance tuning of queries and screens
- Post-deployment enhancements and change requests
- Scheduled health checks and system reviews
- Reduced mean time to resolution on critical issues
- Knowledge transfer to client engineering teams
Standards applied
to this discipline.
Work in this category is developed against the published standards below, applied consistently regardless of the hardware vendor on the line.
Defines the Level 0 to Level 4 functional hierarchy, the equipment model of enterprise, site, area, work centre and work unit, and the object models used to exchange production definition, capability, schedule and performance information between plant control and business systems.
- Equipment hierarchy and naming for the plant model
- Explicit boundary between control and MES layers
- ERP interface reduced to mapping rather than custom build
Specifies the alarm lifecycle: philosophy, identification, rationalization, detailed design, implementation, operation, maintenance, monitoring and assessment, and management of change. Provides the basis for measuring alarm system performance against defined targets.
- Alarm philosophy document and rationalization workshop
- Priority, class, deadband and shelving configuration
- Bad-actor monitoring and performance reporting
A platform-independent, service-oriented architecture for industrial data exchange. Combines an extensible information model with secure transport - authentication, encryption and certificate handling and companion specifications that define domain and device data structures.
- Control-to-enterprise data path across network boundaries
- Information model and address space design
- Certificate-based security between control and IT layers
Twelve steps.
Every engagement.
Each engagement follows the same sequence from discovery through post-commissioning support, so scope, documentation and validation are never negotiated mid-project. Every step closes on a named deliverable.
Discovery
Review of existing equipment, process requirements and production constraints, including what is already installed and what cannot be interrupted.
Requirements Definition
Requirements captured and documented against client specifications and applicable process standards, so scope is agreed before design begins.
Functional Design Specification
Control philosophy, sequence of operations, interlocks and interface requirements written and approved before any software is developed.
IO List Development
A structured input/output list establishing the interface between field hardware and control software, and the reference for both wiring and logic.
System Architecture
Control network, hardware and communication architecture defined across the PLC, HMI, SCADA and MES layers, including addressing and segmentation.
Software Development
PLC, HMI and MES application development to IEC 61131-3 conventions against the approved FDS, using modular and documented code structures.
Simulation
Offline validation of logic and operator screens, including fault paths, before any equipment is available; moving debugging off the production floor.
Factory Acceptance Testing
Structured functional validation against the FDS prior to shipment or site deployment, with defects logged and closed before mobilisation.
Site Acceptance Testing
On-site validation against the approved FDS under live equipment conditions, confirming behaviour matches what was specified and tested.
Commissioning
Equipment energization, sequence validation, interlock proving and production ramp-up support through to stable output.
Training
Operator and maintenance training on system operation, screen navigation and diagnostics, so the plant can run and troubleshoot the system itself.
Support
Post-commissioning remote and on-site support for optimization, change requests and issue resolution, with scheduled system health reviews.
Talk to the
engineer,
not a sales desk.
Production challenges involving unplanned downtime, retrofit planning, MES integration or new line commissioning can be reviewed directly with engineering leadership. Initial technical consultations are used to understand current control architecture, process constraints and desired outcomes before a proposal is issued.
Industrial Automation Project Engineer with 8+ years designing and developing PLC, HMI, SCADA and MES solutions for the automotive and material handling industries.