Smart Manufacturing Execution System for Real-Time Production

On the factory floor, every second counts. The client wanted to see production in real time, catch defects early, and keep suppliers in sync. We delivered a .NET manufacturing execution system that tracks each unit, shows operators exactly what to do, and turns machine signals into clear, actionable dashboards. This lets leaders fix bottlenecks quickly and reduce scrap, while suppliers get faster, more accurate updates.

Challenge

• Blind spots on the line: Managers could not see work in progress or current machine status, so issues were discovered late.
• Late quality detection: Defects appeared at final checks, which led to rework and scrap.
• Supplier lag: Vendors received updates too slowly, which caused shortages or late deliveries.

Solution

• Real time station tracking: Each workstation reports starts, stops, and counts, which builds a live picture of production and overall equipment effectiveness in simple terms, how much value you get from your machines.
• Quality at the source: Inline checks with tolerance rules quarantine suspect parts immediately and create non conformance records with photos and notes.
• Supplier portal: Forecasts, schedules, and electronic kanban signals are shared through a simple web portal and APIs, so upstream partners adjust quickly.

Our manufacturing execution system connects machines, operators, and suppliers, creating a live view of production and ensuring smooth workflows.

Implementation

• Connect to machines safely: We used OPC UA connectors to read signals from PLCs. We standardized events such as start, stop, reject, and downtime reason.
• Event driven core: A fast stream processes factory events, calculates bottlenecks, and highlights stations that need attention right now.
• Operator friendly screens: Large, clear HMIs reduce errors. Multilingual tips and scan first flows minimize typing.
• Gradual rollout: We deployed cell by cell, kept the old process in parallel for a short time, and trained teams with hands on practice.
• Data quality rules: Consistent part IDs, station IDs, and shift calendars keep analytics clean and trustworthy.

Tech stack

• Backend: .NET 8, ASP.NET Core, SignalR for real time, gRPC for fast service calls
• Data: SQL Server for transactions, Azure Data Explorer for time series
• Messaging: RabbitMQ or Azure Service Bus, outbox and saga patterns
• Frontend: Blazor Server for HMIs, React for supplier portal
• Integration and analytics: OPC UA, EDI, REST APIs, Power BI

Call to action

Want clearer lines, fewer defects, and better supplier flow. Partner with Cloudester Software at https://cloudester.com or email [email protected]