MES vs ERP: Shop Floor Integration with AdAstra Software
MES and ERP are not the same thing. But when they work together, they take production efficiency to the top. Explore AdAstra Software's shop floor integration approach and OEE improvement experience.
One of the frequently asked questions in manufacturing digitalization projects is: "Do we need an ERP or a MES?" The correct answer is actually neither alone; both working together.
What Is MES, What Is ERP?
ERP (Enterprise Resource Planning) is the planning and recording system covering all departments of the enterprise. Sales orders, purchasing, finance, inventory, and production orders are managed through ERP. As a rule, ERP tells you *what needs to be produced*.
MES (Manufacturing Execution System) provides real-time monitoring and control of production. Throughout a shift, which machine produced what, how much scrap was generated, which operator ran which work order — all of this is tracked by MES. MES shows *how production is happening*.
Why Do They Complement Each Other?
Even if the ERP system's production plan is correct, shop floor reality may not align with the plan due to machine breakdowns, material delays, or quality rejections. MES bridges this gap by transferring real-time shop floor data to ERP, enabling dynamic plan updates.
AdAstra Software presents these two layers not as separate systems but within an integrated architecture. The result: everyone from the operator to the CFO accesses the same real-time data.
AdAstra Software's Integration Architecture
AdAstra's shop floor integration approach consists of three layers:
*Layer 1 — Field Connectivity:* PLCs, CNC machines, weighing systems, and barcode readers connect to the AdAstra IoT Gateway via OPC-UA or MQTT protocol. Real-time production counters, downtime codes, and quality measurement data are collected on a per-second basis.
*Layer 2 — MES Functions:* Collected raw data is converted into work order-based production quantities, OEE (Overall Equipment Effectiveness) calculations, shift summaries, and operator performance reports. Real-time OEE indicators (Availability, Performance, Quality) can be monitored on dashboards.
*Layer 3 — ERP Feedback:* Actual production quantities, scrap, and rework data calculated at the MES layer are automatically posted to ERP work orders. Inventory levels, cost calculations, and MRP rescheduling are triggered with real data from the shop floor.
OEE Improvement: A Concrete Example
A real scenario from a production facility where AdAstra Software was implemented: the average OEE on a plastic injection line was 54%. After shop floor integration, analysis of downtime causes revealed that 38% of total downtime was attributable to "mold change preparation." Through SMED (Single Minute Exchange of Die) work and work sequence optimization, the same line reached 71% OEE within 4 months.
This type of analysis could have taken months without AdAstra's shop floor data infrastructure. Thanks to real-time downtime coding and automatic shift reporting, we went directly from data collection to analysis.
Who Is It For?
AdAstra Software's MES-ERP integration solution is ideal for enterprises with high daily production volumes, multi-shift operations, and a priority on OEE tracking and capacity optimization. Contact our team to review reference projects in automotive, white goods, plastics, and metalworking sectors.