Rayterton Manufacturing Execution System (MES)

End to End Shop Floor Control

Rayterton Manufacturing Execution System (MES) streamlines manufacturing operations, from order dispatching to work center loading, quality checks, and real-time traceability across 3 plants, 12 lines, and 58 work centers. Our system integrates seamlessly with ERP/MRP, PLCs, IoT, QMS, and WMS for optimal efficiency.

End to End Operating Flow

Rayterton MES runs a clear sequence from order intake to analytics. The same flow works across plants so management can compare performance and drill down without changing definitions. The operating flow starts when ERP sends production orders. MES applies release gate checks, dispatches work to lines, guides operators with digital work instructions, records production and quality results, triggers Andon, maintains genealogy, prints compliance labels, closes the order, then publishes performance analytics and audit packs.

Enterprise Architecture and Integration Map

MES sits in the middle and exchanges structured data with ERP or MRP, WMS, QMS, LIMS, CMMS, SCADA, and BI. Key integration patterns include APIs, webhooks, and connectors with monitoring, retry queue, and safe reprocess. Data flows cover order in, confirmations out, inventory postings, quality results, maintenance work orders, and event streams from edge gateways.

Production Order Inbox and Release Gate

Orders arrive from ERP in an inbox that supports controlled release. The release gate ensures production starts only when prerequisites are met. The release gate checks material readiness, tooling readiness, quality readiness, and capacity readiness. Orders can be approved, kept pending, or blocked with a clear reason. This reduces last minute line stops and prevents execution with missing controls.

Dispatch Sequencing Board and Finite Schedule

This is where MES becomes a scheduling and execution system, not a list of orders. Dispatch is presented as a line based board with shifts and a 2 day horizon. Sequencing supports setup family grouping, changeover awareness, and constraint badges for material, tooling, quality holds, and planned maintenance. Planners can resequence, freeze a window, and flag expedite jobs while keeping trace of what changed and why.

Operator Station and Digital Work Instructions

Operator execution is guided by a task list for the current shift. Each task includes the active step, progress, and required scans so execution stays consistent. Digital work instructions provide clear steps with check points. Scans can be enforced for operator badge, material lot, serial, and tool ID. Actions include start, pause, complete, scrap, rework, and hold. Steps that need supervisor sign off are clearly marked and recorded.

eSign, Shift Handover, and Exceptions Log

Rayterton MES is audit ready because approvals are structured and traceable. Electronic signatures capture who approved, when, and the reason, with the exact scope and context. Shift handover logs record issues, follow up, and next actions. Exceptions capture deviations, rework loops, and hold releases. This keeps operations aligned across shifts and makes investigations faster.

OEE, Loss Tree, and Downtime Pareto

KPI is meaningful only if it can be explained. Rayterton MES breaks OEE into Availability, Performance, and Quality, and links losses to reason codes and events. Downtime timeline shows when stops happen per line. Pareto highlights the top losses and categories such as setup, breakdown, material, and quality. MTBF and MTTR provide a concise reliability view that links back to work centers and events.

Andon Escalation, SLA, and Ownerboard

Calls are tracked with SLA timer, escalation level, owner, and status. Teams can acknowledge, assign, resolve, and add notes. Overdue calls and escalations are visible at a glance so leadership can see response discipline and recurring causes.

In Process Quality Checks, Sampling, Hold, and Release

Sampling schedules and check sheets guide what to measure and when. Results are captured as pass or fail with comments and evidence attachments when needed. A failed check can trigger a hold. Hold release is governed and traceable, and NCR can be created directly from the check outcome.

SPC Control Chart, Rule Violations, and Action Log

Control charts show limits, data points, and rule violations such as trends, beyond limit, and run rules. Violations are listed with details, affected time window, and impact scope. An action log connects the violation to a corrective adjustment or to NCR and CAPA when the issue indicates systemic risk.

NCR and CAPA Workflow with Root Cause and Verification

NCR records include severity, source, line, product, and status. CAPA breaks down tasks into root cause, action plan, owner, due date, evidence, and verification. Approvals and audit trail keep the workflow controlled. Verified closure means the fix was validated, not only completed.

Electronic Batch Record, Review Pack, and Final Approval

The record summarizes material lots, process parameters, and sign offs per step. Deviations and holds are summarized with closure status. Attachments and review checklist form a review pack for final approval. This supports compliance, customer audits, and internal governance.

Traceability and Genealogy Explorer

Traceability is a core differentiator. The genealogy view supports backward trace from finished good to component lots, process steps, QC results, operators, and machines. Forward trace identifies where a component lot was consumed and where finished goods were shipped. Filters include date range, lot, serial, and order. Rework loops are visible so investigations are accurate.

Materials eKanban, Supermarket Call Queue, and Shortage Handling

Material readiness is managed proactively to prevent line stops. eKanban cards track min, max, and current stock, plus ETA replenishment. A call queue connects material requests to pick references and execution status. Shortage alerts include the reason and resolution note, so the system remains auditable and repeatable.

Labeling, Pack, Pallet, Serialization, and Print Queue

Shipping compliance requires controlled labeling and serialization. Label templates are versioned and linked to customer requirements. The pack and pallet structure connects units to cartons and cartons to pallets with SSCC. Print queue shows jobs, printers, quantities, and status, linked to shipment or staging. Serial ranges are clear and traceable across the hierarchy.

Integration Monitor, Retry Queue, and Error Handling

Message monitor tracks ERP orders, confirmations, and inventory postings. Latency, success rate, and failed messages are visible with correlation IDs and reason classes. Retry queue supports safe reprocess with idempotency and guardrails. Example operational scale is 2,400 messages per day with 0.7% failed and 12 items in retry queue.

Multi-Plant Control Tower with Drilldown

This is the executive view that connects outcomes to root causes. KPI tiles cover OEE, throughput, scrap, schedule adherence, and downtime cost, with 30 day trends. Top issues list highlights bottlenecks, quality alerts, and overdue Andon. Drilldown path is consistent and fast: plant to line to work center to event. Leadership can see ranking across 3 plants and then open the exact event chain behind performance gaps.

Glossary

API (Application Programming Interface)
A standard way for software systems to exchange data automatically.

BI (Business Intelligence)
Tools used for reporting, dashboards, and business data analysis.

CAPA (Corrective and Preventive Action)
A process to fix quality problems and prevent them from happening again.

CMMS (Computerized Maintenance Management System)
Software for managing equipment maintenance and maintenance work orders.

EBR (Electronic Batch Record)
A complete digital record for one production batch.

ERP (Enterprise Resource Planning)
The main business system for managing orders, finance, inventory, and production.

IoT (Internet of Things)
Connected devices and sensors that send machine data to software systems.

KPI (Key Performance Indicator)
A key number used to measure performance, such as efficiency or downtime.

LIMS (Laboratory Information Management System)
Software for managing laboratory test data and results.

MES (Manufacturing Execution System)
Software that controls and tracks shop floor production in real time.

MRP (Material Requirements Planning)
A system that calculates what materials are needed for production.

MTBF (Mean Time Between Failures)
The average operating time before equipment breaks down.

MTTR (Mean Time To Repair)
The average time required to repair equipment after a failure.

NCR (Nonconformance Report)
A report for products or processes that do not meet requirements.

OEE (Overall Equipment Effectiveness)
A key metric that combines machine availability, speed, and quality.

PLC (Programmable Logic Controller)
An industrial computer that controls machines and reads machine signals.

QMS (Quality Management System)
Software used to manage quality processes and documentation.

SCADA (Supervisory Control and Data Acquisition)
A system for monitoring and controlling industrial processes.

SLA (Service Level Agreement)
A defined target time for responding to and resolving issues.

SPC (Statistical Process Control)
Statistical methods used to monitor and control process performance.

SSCC (Serial Shipping Container Code)
A unique code used to identify pallets and shipping containers.

WMS (Warehouse Management System)
Software for managing warehouse operations and inventory.