OptiZeus MES
Manufacturing Execution System
The most complete MES platform for manufacturing. Production, quality, SPC, CAPA, OEE, CMMS, batch recipes, warehouse, labor, EHS safety, energy, ERP integration, OPC-UA, MQTT, and Active Directory — with built-in 3-level OT/IT network separation.
Core Production
Real-Time Dashboard
Live KPI overview with SCADA status, order breakdowns, charts, and recent activity feed.
- Live KPI cards
- SCADA online/offline status
- Dashboard charts
- Recent activity feed
Production Order Management
Full lifecycle tracking from planned to completed. Manage priorities, quantities, operations, and scrap rates.
- Order lifecycle tracking
- Operation sequencing
- Priority management
- Scrap rate monitoring
Bill of Materials (BOM)
Multi-level BOM management with versioned product master data. Define components, quantities, and sequences.
- Multi-level BOM
- Product versioning
- Component management
- Links to production orders
Batch / Recipe Engine
Versioned recipe management with approval workflows. Execute batches with parameter tracking against target/min/max values.
- Recipe versioning & approval
- Batch execution tracking
- Critical parameter limits
- Product-recipe linking
Quality & Compliance
Quality Management
In-process, final, and incoming inspections with tolerance tracking. NCRs with root cause analysis and corrective actions.
- Multi-stage quality checks
- NCR management
- Severity classification
- Inspector digital sign-off
SPC Charts
Statistical Process Control with X-bar/R charts. Define parameters with UCL/LCL limits, record measurements, and track Cpk.
- X-bar / R chart types
- UCL & LCL limits
- Measurement tracking
- Process capability stats
CAPA Management
Corrective and Preventive Actions linked to NCRs. Five-Why root cause analysis, action plans, task assignments, and overdue tracking.
- Five-Why root cause analysis
- Action plan tracking
- Task assignments & deadlines
- Overdue CAPA alerts
Electronic Signatures
21 CFR Part 11 compliant e-signatures. Password-authenticated signing with cryptographic hash verification.
- Password-authenticated signing
- Signature hash verification
- Complete signature log
- 21 CFR Part 11 compliant
Audit Trail
Complete activity logging for regulatory compliance. Every action recorded with timestamps, IP addresses, and user details.
- Full activity logging
- Filter by module/user/action
- IP address tracking
- 21 CFR Part 11 ready
Traceability & Inventory
Product Genealogy & Lot Tracing
Forward and backward traceability for complete product genealogy. Track materials from raw inputs to finished goods.
- Forward/backward tracing
- Lot lifecycle tracking
- Material consumption records
- Recall-ready traceability
Material Traceability
Full material chain traceability with trace numbers. Forward and backward trace queries linked to lots and products.
- Trace number management
- Forward/backward queries
- Material type tracking
- Status lifecycle
Inventory Management
Multi-location stock tracking with transactions (receive/issue/transfer) and low stock alerts with reorder points.
- Warehouse locations
- Stock transactions
- Reorder point alerts
- Lot-level tracking
Warehouse Management
Zone and bin location management with pick orders. Temperature-controlled zones, bin availability, and pick/put-away workflows.
- Zone & bin management
- Pick/put-away orders
- Temperature-controlled zones
- Bin availability tracking
Equipment & Maintenance
Maintenance CMMS
Full CMMS with asset registry, preventive maintenance plans, work orders, spare parts, and MTBF/MTTR metrics.
- Asset management
- Preventive maintenance plans
- Work orders & spare parts
- MTBF / MTTR statistics
Downtime Tracker
Track planned and unplanned downtime with reason codes. Pareto analysis and summary analytics for root cause identification.
- Planned/unplanned tracking
- Reason code library
- Pareto analysis
- Downtime summary analytics
OEE Dashboard
Overall Equipment Effectiveness with Availability, Performance, and Quality breakdowns. Trend analysis and cross-machine comparison.
- A x P x Q calculation
- Per-work-center trends
- Cross-machine comparison
- Shift-level OEE records
Tool Management
Tool registry with lifecycle tracking, calibration scheduling, usage logging, and remaining life calculations.
- Tool lifecycle tracking
- Calibration scheduling
- Usage logging per work order
- Remaining life calculation
Operations & Workforce
Digital Work Instructions
Step-by-step SOPs with version control, image support, and required digital acknowledgment from operators.
- Versioned SOPs
- Step-by-step guidance
- Image support
- Digital signoff required
Work Center Scheduling
Capacity-aware scheduling with work center status management. Identify bottlenecks and optimize utilization.
- Capacity planning
- Work center status
- Shift planning
- Bottleneck identification
Shift Manager
Define shifts with break times, assign operators to work centers, and maintain handoff logs with safety notes.
- Shift definitions
- Operator assignments
- Handoff logs
- Safety notes tracking
Labor Management
Employee registry, skill matrix, proficiency levels, time entry tracking, and cross-functional skill gap analysis.
- Employee skill matrix
- Proficiency levels (1-5)
- Time entry per work order
- Skill gap analysis
Training Records
Course management, completion tracking, recertification schedules, compliance matrix, and training gap identification.
- Course & certification tracking
- Recertification schedules
- Compliance matrix
- Training gap alerts
User Management & RBAC
Role-based access control with four levels: Admin, Supervisor, Operator, and Viewer. Full account lifecycle management.
- 4-level RBAC
- Account enable/disable
- Password reset
- Role assignment
Active Directory / LDAP
Enterprise SSO with Active Directory and LDAP integration. Auto-create users, map AD groups to MES roles, and sync on schedule.
- LDAP / AD connection
- AD group → MES role mapping
- Auto-create users on login
- Scheduled user sync
Connectivity, Monitoring & Integration
SCADA Live View
Real-time PLC tag monitoring with configurable refresh. Live SCADA connection status and OEE metrics.
- Live PLC tag values
- Configurable refresh rate
- SCADA connection status
- Real-time OEE metrics
Reports & Export
Production, quality, NCR, and lot trace reports with date range filters. PDF and CSV export.
- Production summary
- Quality & NCR reports
- Lot trace reports
- PDF & CSV export
Analytics Dashboard
Custom KPI definitions with formulas, configurable dashboards with widgets, and periodic KPI snapshots.
- Custom KPI formulas
- Configurable dashboards
- Chart & gauge widgets
- KPI snapshot history
Notification System
Configurable email alerts for critical NCRs, order completions, quality failures, and lot quarantine events.
- Critical NCR alerts
- Order completion notifications
- Quality failure alerts
- SMTP email integration
ERP Integration
Connect to SAP, Oracle, and other ERPs. Field mapping, auto-sync scheduling, and sync log tracking.
- SAP / Oracle / custom ERP
- Field mapping editor
- Auto-sync scheduling
- Sync log & statistics
OPC-UA Client
Native OPC-UA client for direct PLC communication. Browse server nodes, configure tags with data types, and read live values.
- OPC-UA server browsing
- Tag node ID configuration
- Data type mapping
- Live value polling
MQTT Client
Built-in MQTT broker connection for IoT and edge devices. Subscribe to topics, publish messages, and view live message streams.
- Topic subscribe & publish
- QoS level control
- Live message stream
- Retain flag support
Shop Floor Display
Dedicated floor display mode for large screens. Show live production KPIs, OEE, and status on the shop floor with optional public access.
- Full-screen display mode
- Live production KPIs
- Configurable layouts
- Public access option
Safety & Sustainability
EHS / Safety Management
Incident reporting, safety inspections, hazard assessments with risk matrices. Track lost time, near misses, and corrective actions.
- Incident reporting & tracking
- Safety inspections & checklists
- Hazard risk matrix
- Lost time & near miss tracking
Energy Management
Monitor electricity, gas, water, and steam consumption. Meter readings, cost tracking, and monthly/annual targets.
- Multi-utility meter tracking
- Cost per unit calculation
- Consumption analytics
- Monthly/annual targets
Document Management
Controlled document system with versioned revisions, approval workflows, and operator acknowledgment tracking.
- Versioned document control
- Revision history
- Approval workflows
- Acknowledgment tracking
3-Level OT / IT Separation
Both OptiZeus SCADA and MES support a secure 3-level network architecture with proper separation between Operational Technology (OT) and Information Technology (IT) networks. An MQTT broker and OPC-UA gateway in the DMZ ensure no direct cross-network connections.
Two Protocols, Complete Coverage
MQTT and OPC-UA work together through the DMZ. Nothing in IT can directly reach OT — both protocols pass through the security boundary.
- Real-time streaming data
- OT → IT (publish/subscribe)
- 1000s of values/second
- Port 1883 / 8883 (TLS)
- Structured reads & writes
- IT ↔ OT (bidirectional)
- Browse PLC tag trees
- Port 4840 (certificate auth)
Security by Design
- OT Network Isolation — SCADA runs on a dedicated OT network with PLCs, no internet access
- DMZ Layer — MQTT broker and OPC-UA gateway in a protected DMZ, firewalled on both sides
- Authenticated Channels — Certificate-based or token-based auth on all OPC-UA and MQTT connections
- Live OEE Flow — Equipment metrics stream from SCADA through DMZ to MES without exposing the OT network
- PLC Monitoring — Tag values, alarms, and counters flow through the secure DMZ channel
Why OptiZeus MES?
Transform your manufacturing operations with a modern, integrated platform
Regulatory Compliance Ready
Built-in support for industry standards and regulatory requirements
FDA / GMP
Genealogy, lot tracing, CAPA, and e-signatures for pharmaceutical compliance
ISO 9001
Quality management with NCR workflows, SPC, CAPA, and corrective actions
FSMA
Food safety traceability with material consumption and recall-ready genealogy
ISO 22000
Food safety management system with hazard assessments and inspections
21 CFR Part 11
Electronic signatures, audit trails, and cryptographic verification
IATF 16949
Automotive quality management with SPC, tool calibration, and traceability
ISO 45001
EHS safety management with incident tracking and hazard risk matrices
ISO 50001
Energy management with meter monitoring, consumption analytics, and targets
IEC 62443
3-level OT/IT network separation with DMZ, firewalls, and authenticated channels
Ready to digitize your manufacturing?
OptiZeus MES + SCADA gives you complete visibility from the ERP level down to every sensor on the plant floor.