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OptiZeus-MES-Technical-Datasheet.pdf
Technical Datasheet
OptiZeus MES
35-Module Manufacturing Execution System — Technical Specifications
System Architecture
| Backend | Node.js + Express (port 6000) |
| Frontend | React 18 (CRA, port 6001 dev / served by backend in production) |
| Database | PostgreSQL (port 5432) |
| Authentication | JWT with bcryptjs, 4 roles: Admin, Supervisor, Operator, Viewer |
| License | AES-256-CBC hardware-locked, 3 tiers (Starter / Professional / Enterprise), 7-day trial |
| SCADA Integration | HTTP client to OptiZeus SCADA API (configurable via SCADA_URL env var) |
| OPC-UA | Built-in OPC-UA client with browse, read, write, and subscription support |
| MQTT | Built-in MQTT client with subscribe, publish, QoS 0/1/2, retain, and TLS |
Core Production Modules
| Module | Key Capabilities |
|---|---|
| Dashboard | Live KPIs, SCADA status indicator, order breakdown charts, recent activity feed |
| Production Orders | Full lifecycle (Planned > In Progress > Completed), operation sequencing, scrap tracking |
| BOM Manager | Multi-level BOM with product versioning, component quantities, and sequence numbers |
| Batch / Recipe | Versioned recipes, approval workflows, batch execution with target/min/max parameters |
| Scheduling | Capacity-aware scheduling, work center status, shift planning, bottleneck identification |
Quality & Compliance Modules
| Quality Mgmt | In-process, final, incoming inspections. NCR management with severity, root cause, corrective actions |
| SPC Charts | X-bar/R charts, UCL/LCL limits, measurement recording, Cpk/Cp statistics |
| CAPA | Corrective/Preventive actions, Five-Why analysis, task assignments, deadlines, overdue alerts |
| E-Signatures | 21 CFR Part 11 compliant. Password-authenticated, cryptographic hash, full signature log |
| Audit Trail | Every action logged: timestamp, user, IP, module, action type, before/after values |
Traceability & Inventory
| Genealogy | Forward/backward traceability, lot lifecycle, material consumption, recall-ready |
| Material Trace | Trace numbers, forward/backward queries linked to lots and products, status lifecycle |
| Inventory | Multi-location stock, receive/issue/transfer transactions, reorder points, lot-level tracking |
| Warehouse | Zone/bin management, pick/put-away orders, temperature-controlled zones, bin availability |
Equipment & Maintenance
| CMMS | Asset registry, PM plans, work orders, spare parts inventory, MTBF/MTTR statistics |
| Downtime | Planned/unplanned tracking, reason codes, Pareto analysis, duration analytics |
| OEE | Availability x Performance x Quality. Per-work-center trends, shift-level records, cross-machine comparison |
| Tool Mgmt | Tool registry, calibration scheduling, usage logging per work order, remaining life calculation |
Operations & Workforce
| Work Instructions | Versioned SOPs, step-by-step with images, digital acknowledgment required |
| Shift Manager | Shift definitions with breaks, operator-to-work-center assignments, handoff logs |
| Labor Mgmt | Employee registry, skill matrix (1-5), time entry per work order, skill gap analysis |
| Training | Course management, completion tracking, recertification schedules, compliance matrix |
| Active Directory | LDAP/AD connection, AD group to MES role mapping, auto-create users, scheduled sync |
| User Mgmt | 4-level RBAC (Admin/Supervisor/Operator/Viewer), enable/disable, password reset |
Safety & Sustainability
| EHS / Safety | Incident reporting, safety inspections, hazard risk matrix, lost time tracking, near misses |
| Energy | Multi-utility meters (electric/gas/water/steam), cost/unit, monthly/annual targets, analytics |
| Documents | Controlled document system, versioned revisions, approval workflows, acknowledgment tracking |
Connectivity & Integration
| SCADA Live | Real-time PLC tag values, connection status, OEE gauges, auto-refresh 5-60s |
| OPC-UA Client | Browse server nodes, configure tag node IDs, data type mapping, live polling |
| MQTT Client | Broker connection, topic subscribe/publish, QoS 0/1/2, retain, live message stream |
| ERP Integration | SAP/Oracle/custom, field mapping editor, auto-sync scheduling, sync logs |
| Reports | Production, quality, NCR, lot trace reports. PDF and CSV export |
| Analytics | Custom KPI formulas, configurable dashboards, chart/gauge/table widgets, snapshot history |
| Notifications | Email alerts (SMTP) for NCRs, order completions, quality failures, lot quarantine |
| Floor Display | Full-screen mode for shop floor TVs, live KPIs, optional public access |
OT/IT Network Architecture
| Layer | Components | Protocols |
|---|---|---|
| IT (Level 3-4) | OptiZeus MES, PostgreSQL, ERP, Active Directory, Browser clients | HTTPS, LDAP, REST API |
| DMZ (Level 2.5) | MQTT Broker (Mosquitto/HiveMQ), OPC-UA Gateway (Kepware/Matrikon) | MQTT (1883/8883), OPC-UA (4840) |
| OT (Level 0-2) | OptiZeus SCADA, PLCs (Siemens, AB, Schneider), Sensors, I/O | S7, EIP, Modbus, OPC-UA, MQTT |
Database Schema
| Tables | 22+ tables covering all 35 modules |
| Key Tables | users, production_orders, quality_checks, products, bom_items, inventory, work_orders, oee_records, audit_log |
| Relations | Full foreign key relationships with cascading deletes where appropriate |
| Indexes | Optimized indexes on frequently queried columns (timestamps, status, user_id) |
System Requirements
MES Server
- Windows 10/11 or Linux (Ubuntu 20.04+)
- Node.js 18+ LTS
- PostgreSQL 14+
- 4+ GB RAM (8 GB recommended)
- 4+ CPU cores
- 20+ GB disk space
Client Browser
- Chrome 90+, Edge 90+, Firefox 90+
- 1920x1080 recommended
- Network access to MES server (port 6000)
- No client installation required
For detailed specifications or a technical consultation:
www.zeus-automation.org | info@zeus-automation.com