Production managers walking the floor to get status because the MES doesn't show real-time machine conditions?
Finished goods lot traceability requiring manual paper trail reconstruction when a quality issue is discovered?
Work orders printed and tracked on clipboards because the system doesn't reach the operators on the line?
Downtime events going unrecorded because there's no easy way for operators to log the reason?
Production managers should know machine status, OEE, and work order progress from a screen, not by walking the floor. A well-built MES connects your shop floor to your planning team so decisions happen on data, not on what someone remembered from the last shift.
We build custom Manufacturing Execution Systems for discrete, process, and mixed-mode manufacturers. From production order release to finished goods traceability, we cover the full production cycle and integrate with your ERP so inventory and schedules stay in sync.
Real-time machine and line monitoring with OEE, downtime, and cycle time dashboards
Production order management and work order tracking from release to completion
Lot and serial traceability from raw material through every production stage to finished goods
Quality inspection at production stages with pass/fail recording and non-conformance flagging
A Manufacturing Execution System (MES) bridges the gap between ERP and the shop floor by tracking production orders, machine status, quality checks, and material consumption in real time. It captures genealogy data from raw material to finished goods, so traceability is instant rather than manual. RaftLabs builds custom MES software tailored to your production environment and ERP stack.
Off-the-shelf MES platforms are built for the median factory. If your production environment has unusual routing logic, a mix of manual and automated stations, or an ERP that doesn't play well with standard connectors, a generic platform forces you to work around it. That workaround usually means spreadsheets next to the system, which is where data quality breaks down.
A custom MES is scoped to your production process. It captures what your operators actually do, surfaces the information your planners need, and pushes the right data back to your ERP without a manual rekeying step. The result is a system people use because it fits the job, not one they tolerate.
We work with discrete manufacturers, process manufacturers, and mixed-mode facilities. Whether you run make-to-order, make-to-stock, or configure-to-order, we model your production logic accurately before we write a line of code.
We build the full order lifecycle into your MES. Production orders released from your ERP appear on the shop floor with the correct routing, BOM, and instructions. Operators confirm start and completion at each step, and supervisors see work order progress without having to ask. Partial completions, splits, and rework orders are handled without workarounds. Order status flows back to your ERP so inventory and scheduling stay current.
Connect your machines to the MES via OPC-UA, MQTT, or direct PLC integration. Track runtime, idle time, and downtime by reason code. Calculate OEE automatically for each machine, line, and shift. Supervisors see a live floor view and get alerts when a machine drops below threshold. Downtime reason codes are captured at the operator level so you have accurate data for root cause analysis, not just totals.
Define inspection plans tied to operation steps, product types, or customer requirements. Operators record pass/fail results, measurements, and visual checks at the point of production, not at the end of the line. Non-conformances are flagged immediately and routed to quality for disposition. Inspection history is stored against each work order and lot so audit responses are fast and accurate.
Track material consumption against each work order at the component level. Backflushing or manual issue are both supported depending on your process. The MES records which lot of each component went into each finished goods lot, which is the foundation of full genealogy traceability. Variance between planned and actual consumption is visible in real time so material shortages surface before they stop production.
Assign operators to work centres and shifts. Record which operator performed each operation and when. Track productivity by operator, shift, and team without manual data collection. Shift handover summaries pull together order status, machine status, and open quality issues automatically. Supervisors spend less time compiling reports and more time on the floor.
Record every component lot consumed in every work order, at every production stage, tied to the finished goods lot or serial number. When a quality issue is found in the field, you trace forward and backward through the entire production tree in seconds rather than hours. Traceability reports are generated on demand and formatted for customer or regulatory requirements without manual assembly from paper records.
Frequently asked questions
A focused MES covering production order management, basic machine monitoring, and quality inspection at key stages typically takes 12 to 16 weeks from requirements sign-off to go-live on a pilot line. Full genealogy traceability and ERP integration add time depending on your ERP and the complexity of your BOM structure. We scope precisely before committing to a timeline so there are no surprises at week eight.
We have built integrations with SAP, Microsoft Dynamics 365, Oracle NetSuite, Epicor, and Infor. Integration approach depends on what your ERP exposes. We use REST APIs, SOAP web services, database-level integration, or flat-file exchange where API access is limited. Production order release, inventory movements, and work order confirmations are the standard integration points. We document the integration spec before development starts.
Yes. Machines without network connectivity can be monitored through operator terminals, barcode scanners, or low-cost I/O modules attached to existing machine signals such as a cycle complete relay. We design the data capture method to fit your equipment, not the other way around. For newer machines with OPC-UA or MQTT support, we connect directly. The MES consolidates both into the same monitoring view.
Traceability records are stored in a relational database with a data model designed specifically for production genealogy queries. Retention period is configured to your requirements, whether that is three years for internal quality purposes or fifteen years for regulated industries. Traceability queries are optimised so a full forward or backward trace on a complex multi-level BOM returns results in seconds, not minutes.
Tell us about your production environment and what you need to track. We'll scope a solution that fits your process and your budget.