OptiZeus MES
Manufacturing Execution System
The most complete MES platform for manufacturing. Production, quality, SPC, OEE, CMMS, batch recipes, warehouse, OPC-UA, MQTT, Active Directory — with built-in 3-level OT/IT network separation.
Complete MES Platform
Every module you need to digitize manufacturing operations — from production orders to EHS safety.
Core Production
Real-Time Dashboard
Live KPI overview with SCADA status, order breakdowns, charts, and recent activity feed.
Production Orders
Full lifecycle tracking from planned to completed. Priorities, quantities, operations, and scrap rates.
Bill of Materials
Multi-level BOM management with versioned product master data and component sequences.
Batch / Recipe Engine
Versioned recipe management with approval workflows and parameter tracking.
Quality & Compliance
Quality Management
In-process, final, and incoming inspections with NCR workflows and root cause analysis.
SPC Charts
Statistical Process Control with X-bar/R charts, UCL/LCL limits, and Cpk tracking.
CAPA Management
Corrective and Preventive Actions with Five-Why root cause analysis and task assignments.
Electronic Signatures
21 CFR Part 11 compliant e-signatures with cryptographic hash verification.
Audit Trail
Complete activity logging with timestamps, IP addresses, and user details.
Traceability & Inventory
Product Genealogy
Forward and backward traceability for complete product genealogy and lot tracing.
Material Traceability
Full material chain traceability with trace numbers and status lifecycle.
Inventory Management
Multi-location stock tracking with transactions, reorder points, and lot-level tracking.
Warehouse Management
Zone and bin management with pick/put-away workflows and temperature-controlled zones.
Equipment & Maintenance
Maintenance CMMS
Full CMMS with asset registry, preventive maintenance, work orders, and MTBF/MTTR.
Downtime Tracker
Planned/unplanned downtime with reason codes, Pareto analysis, and summary analytics.
OEE Dashboard
Overall Equipment Effectiveness with A x P x Q calculation and trend analysis.
Tool Management
Tool lifecycle tracking, calibration scheduling, usage logging, and remaining life.
Operations & Workforce
Digital Work Instructions
Versioned SOPs with step-by-step guidance, image support, and digital signoff.
Scheduling
Capacity-aware scheduling with work center status and bottleneck identification.
Shift Manager
Shift definitions, operator assignments, handoff logs, and safety notes.
Labor Management
Employee skill matrix, proficiency levels, time entry, and skill gap analysis.
Training Records
Course management, recertification schedules, and compliance matrix.
User Management & RBAC
Role-based access control: Admin, Supervisor, Operator, and Viewer.
Active Directory / LDAP
Enterprise SSO, AD group to MES role mapping, auto-create users, scheduled sync.
Connectivity, Monitoring & Integration
SCADA Live View
Real-time PLC tag monitoring with configurable refresh and live OEE metrics.
Reports & Export
Production, quality, NCR, and lot trace reports with PDF and CSV export.
Analytics Dashboard
Custom KPI definitions with formulas, configurable dashboards and widgets.
Notification System
Configurable email alerts for NCRs, order completions, and quality failures.
ERP Integration
Connect to SAP, Oracle, and custom ERPs with field mapping and auto-sync.
OPC-UA Client
Native OPC-UA client for direct PLC communication. Browse nodes, read live values.
MQTT Client
Built-in MQTT broker connection. Subscribe/publish topics, QoS control, live streams.
Shop Floor Display
Full-screen production KPIs for large screens with optional public access.
Safety & Sustainability
EHS / Safety
Incident reporting, safety inspections, hazard assessments, and risk matrices.
Energy Management
Multi-utility meter tracking, cost per unit, consumption analytics, and targets.
Document Management
Controlled document system with versioned revisions and approval workflows.
3-Level OT/IT Separation
Secure network architecture with MQTT and OPC-UA through a DMZ. No direct connection between IT and OT networks.
MQTT
Real-time streaming from OT to IT via publish/subscribe. Place the broker in the DMZ — SCADA publishes, MES subscribes.
- 1000s of values/second
- Topic-level security
- QoS 0/1/2 control
- TLS on port 8883
- Mosquitto / HiveMQ / EMQX
OPC-UA
Structured bidirectional communication through an OPC-UA gateway in the DMZ. Browse tags, read values, write setpoints.
- Bidirectional read/write
- Certificate-based auth
- PLC tag tree browsing
- Port 4840 (standard)
- Kepware / Matrikon / Prosys
OT Isolation
SCADA runs on a dedicated OT network with PLCs. No internet access required.
DMZ Boundary
MQTT broker + OPC-UA gateway in a firewalled DMZ. No direct IT-to-OT path.
Authenticated Channels
Certificate or token-based auth on all connections across the security boundary.
Regulatory Ready
Built-in support for industry standards and regulatory requirements.
How Does OptiZeus MES Compare to Siemens Opcenter?
35 modules included, 10–50x lower cost, multi-vendor PLC support, and no vendor lock-in.
See Full ComparisonReady to Digitize Your Manufacturing?
OptiZeus MES + SCADA gives you complete visibility from ERP to every sensor on the plant floor — with secure 3-level OT/IT separation.