Features of the iTAC.MES.Suite

Many years of experience, continuous development and our never-ending striving for innovation have made our iTAC.MES.Suite one of the leading MES solutions on the market today.  

With our strong focus on our customers' needs and constant monitoring of market trends, our solution offers capabilities focused on usability and interface compatibility.

Learn more about the core features of our iTAC.MES.Suite.

Nowadays manufacturing companies face the inevitable challenge of remaining competitive in the fast-paced, global market. For this purpose, it is mandatory to create internal processes in the most efficient way and reduce costs at the same time. To make sure that all structures and processes are nonetheless permanently oriented to the customers' needs, iTAC.MES.Suite offers the possibility to map the entire production in real time and simultaneously shows potentials for optimization.

  • Standard ERP Integration
  • Standardized connectivity adapter through EAI-Schema
  • Import of master data (work order, BOM, routing), material information and equipment information
  • Transfer monitoring
  • Work orders can be generated manually with the MES
  • Generation of work orders based on pre-defined rules with information about the sales orders from the ERP and the PLM
  • Automated scheduling of work orders based on availability of machines, tools, worker and material 
  • Multiple targets can be defined (one time delivery, limited WIP, ..)
  • Current status based on real time feedback from the floor can be considered for (re-)planning when issues occur

Real-time updating of the production plan

  • Direct feedback from the production floor on produced quantities, machine availability, tool availability and current production time at each work step
  • Direct feedback regarding material availability in stock as well as on the shop floor
  • Consolidation of all information impacting the production plan

Alerts about issues with the workflow

  • Calculate planned future impact based on real-time feedback
  • Graphical display of all issues including the root cause

Recommendations to solve malfunctions

  • Tool provides recommendations on how to fix malfunctions
  • Tool shows impact on other work orders
  • Calculation of the total costs in case of a change of the production plan with various scenarios is possible
  • Automated or manual start of work orders on the floor
  • Real time tracking of the status including WIP, consumed material, issues, etc. 
  • Automated execution of the work order based on the defined routing
  • Automated loading of recipes, work instructions, repair instructions, etc. on machines and workstations on the shop floor
  • All recipes, documents and rules are uploaded in the MES or links to them will be saved
  • Only released versions can be used in production
  • Version in relation to work order, BOM and routing is tracked
  • Multiple approval level including e-mail notification for approval are included to fulfill compliance requirements
  • Fool proved assembly with work order instructions and graphical guidelines
  • Merge function for material
  • Automated distribution of work steps
  • Controlling of the repair process
  • Automated upload of test results per serial number
  • Drag-and-draw relationship between test result, root cause and repair action
  • Display of all product related data to support the repair process
  • Analysis and tracking of failures including tracking of major causes
  • Display of CAD information for the electronics industry possible (incl. highlighting of defects) 
  • Operator terminal to control production and to enter information 
  • Display of current production status
  • Direct connection of reports and BI allows easy changes and updates
  • Simplified failure assignments for OEE reporting
  • Production and machine data acquisition (PDA/MDA)
  • Tracking the required time for specific work steps, machines and work orders
  • Input via operator terminal for multiple machines possible
  • Automated tracking via machine login possible
  • Automated tracing of machine status and messages
  • Automatic calculation of required material (per station/line)
  • Complete integration with AGV systems and automatic tower storage systems for material transport
  • Automatic updating of material consumption (including feedback to other systems such as ERP)
  • Automatic relabeling functionality for goods receiving
  • Support of various material replenishment concepts such as KANBAN
  • Easy packaging options
  • Visual guidance
  • Configurable shipping rules
  • Confirmation and assignment of individual items to lots
  • Automatic generation of labels for packaging and shipping
  • Automatic generation of documentation for various devices
  • Global reporting functionality including a central data warehousing option
  • Availability of reports possible via cloud access
  • All reports are HTML5-based and can be viewed with any mobile device as well as via stationery PCs

 Equipment maintenance

  • Integration into existing maintenance solutions via ERP service
  • Avoidance of equipment degradation by carrying out maintenance activities regularly
  • Maintenance is carried out under consideration of technical specifications, workflows or manufacturer specifications, e.g. after a certain number of uses, duration or after a pre-defined maintenance interval
  • Maintenance planning via iTAC.APS.Service

Equipment inspection

  • Periodic execution of equipment inspection with specified workflow
  • Inspections are done for the purpose of plant integrity and safe working conditions
  • The goal is to keep the KPIs of the plants as high as possible (e.g. Overall Equipment Effectiveness, OEE)

Equipment repair

  • Restoration of an installation from a defective to a functional state
  • Both the exchange of parts and the reprocessing are supported (parts are reworked)
  • Integration of workflows for execution of repairs, assessment of the equipment condition and release 
  • Equipment history, actual equipment assembly status

The modular, platform-independent iTAC.MES.Suite is able to communicate through standardized interfaces with ERP systems and machines irrespective of their age or the manufacturer. By linking the software to already running systems the solution contributes to the consolidation and harmonization of the existing, production-related IT-landscape. As a result, you obtain a simple vertical as well as horizontal integration from shop floor to top floor in your company.

  • Direct Integration through API between iTAC.MES.Suite and equipment
  • No hardware required, substantially reduced integration complexity and effort
  • API libraries and off-the-shelf connectors for major equipment vendors

 

API/REST API

  • Public and backward compatible API interfaces
  • API also exposed as REST interfaces for HTML5/Web applications
  • WEB based API Portal for documentation and testing using Swagger UI

 

PLC Integration

  • OPC UA Support for data access and methods
  • Integration of PLC controlled equipment without coding
  • Industrial communication standard
  • Supports consistent client-server communication transfer (OPC UA methods)
  • End-to-end secure communication between PLC and iTAC.MES.Suite
  • Integration via off-the-shelf hardware basic.MES.Device
  • Connection to brown-field installations without modifying equipment
  • Cost-efficient due to the use of off-the-shelf components 
  • UI supports various use cases through configuration and custom server functions
  • SMEMA and digital I/O ports to control conveyers and material flow between plants
  • Replicate data from production database (DB) in real time
  • Unique feature compared to traditional data replication software: enables data cleaning on production
  • Database without compromising the replicated Database
  • Works with any database size and Oracle Standard Edition
  • Ensures integrity of database
  • Configurable replication rules
  • Seamless access to production and archived data

Especially in discrete manufacturing, companies are dependent on ensuring complete traceability of the goods produced. There are various industries in which in addition to the Product Liability Act, there are several other standards and regulations that require complete proof of production material and process data. These requirements are all met by the use of the iTAC.MES.Suite. As a pioneer in the area of traceability, iTAC offers the best prerequisites for a transparent manufacturing process.

  • Online connection of all process steps which are relevant for production (machines, manual workstation, ..) 
  • Various possibilities for the connection of old plants and machines without interfaces (incl. the Raspberry Pi based basic.MES.Device)
  • Full API interaction with over 110 machine suppliers 
  • Collection of all data including test results, recipes, settings, operators, etc.
  • Verification of master data , recipes, settings, qualifications of workers, tools, materials, etc. 
  • Immediate stopping of plants and processes possible
  • Verification of the number of repair interventions
  • Q-Hold and Pre-Q-Hold options for semi-finished and finished goods
  • Trace Up (from material to serial number) and Trace Down (from serial number to material) functionalities
  • Immediate intervention in production, such as blocking material or serial numbers, is possible
  • Cross-plant transfer of records from device history and supply chain traceability (SCT)

In the course of digitalization, countless data are generated everywhere. The ability to master these amounts of data opens up new potentials and perspectives for companies that drive us forward. Using advanced analytics and business intelligence (BI) tools, the data collected - both structured and unstructured - is converted directly. The resulting Smart Data provides information on efficiency and productivity and thus identifies optimization potential. 

  • Highly performant analysis of Big Data with the iTAC.BI.Service
  • Inclusion of structured data from the MES and unstructured data from the IIoT
  • Visualization of analysis results, production KPIs, tracking & tracing information, etc. 
  • Enterprise reporting on different levels (group, plant, line, station)
  • Flexible reporting for various industries such as electronics, automotive, mechanical, etc. 
  • Decoupled data management for production and visualization
  • Drag and drop report-designer is easy to use
  • Developer environment for a highly flexible and adaptable design
  • Data visualization in the IIoT.Portal
  • HTML frontend for all devices with web browser (PC, Tablet, Mobile)
  • Structured presentation framework with self service and integration layer
  • Flexible and adaptable HTML5 visualization
  • Joining structured and unstructured data from diverse sources 
  • Data cleansing 
  • Correlation analysis between machine conditions (MES, structured data) and measurements (IIoT, unstructured data)
  • Visualizing and evaluation the now generated data inclidung a root cause analysis
  • Predictive maintenance functionalities

The iTAC.MES.Suite provides a software solution that enables simple integration into existing processes and structures due to its high degree of standardization. Through countless possibilities for configuring the standard solution and adapting it to the conditions on-site, each customer receives an individual software package that is precisely tailored to his requirements. Regular updates ensure that all customers worldwide are immediately provided with the latest functions and features. 

  • One base software for all verticals
  • All 220 installations of the iTAC.MES.Suite are using the standard base-software
  • Every software installation, even if it is highly customized, can upgrade to the latest version of the iTAC.MES.Suite
  • Factory layout and processes can be configured
  • Standard clients and functions are configurable to meet various customer requirements
  • Some interfaces (OPC UA) and the business logic can be generated by drag and draw tools
  • API interfaces and displayed data are available for developers to create their own clients and solutions as add-ons to the iTAC.MES.Suite
  • iTAC offers a development framework to their customers allowing them to expand the code developed and designed by iTAC
  • HTML5 clients and microservices can be integrated
  • Framework Integration layer for client integration

The iTAC.MES.Suite enables a comprehensive view of production and operation in real time through integrated, standardized ERP interfaces. This closes the existing gap between ERP and machine level, and combines the core competencies of both systems. In addition to SAP, the iTAC solution also supports almost any other ERP systems. 

  • Integration in ERP, SCM, PDM & PLM
  • Standard SAP interface
  • Transferable interface for other ERP's
  • All data will be checked for consistency
  • No data transfer in case the data can't be processed 
  • EAI tool for fast integration
  • Drag and draw connections between data point
  • Integration of automated data transfer
  • Various external systems and protocols are supported
  • Conversion of external protocol into XML standard
  • Reliable multi-tier architecture with failover
  • Analytics service to support PLM processes
  • Integration of automated data integration
  • Collect as much data as necessary in a separate analytics platform
  • Combine multiple criteria for the analytics process such as raw material details, equipment data or production environment information

The modular, scalable iTAC.MES.Suite is based on standards, which makes the use of the solution quick and uncomplicated without additional installation of plug-ins. The software can be operated both on-premises and via cloud installation. By using different microservices and monitoring tools, the various requirements and needs of our customers can be met. This makes the iTAC.MES.Suite a comprehensive solution that helps companies from different industries to increase efficiency, productivity and profitability. 

  • Java EE, web standards and open source components
  • RESTful APIs with client application approach based on HTML5 components
  • Microservices to reduce time to market
  • Docker to faciliate deployment
  • Scalability and redundancy available on-premises and via cloud
  • Synchronous and asynchronous communication (publish/subscribe) via API
  • MES cloud installation has been tested on Amazon Web Service and private data center
  • Online communication between cloud MES and shopfloor through optimized protocols
  • Secure communication using SSL/TLS (https) or VPN tunnels
  • MES as a Service, consumption based payment, low upfront investment for hardware and software
  • Access to managed cloud platform services (PaaS)
  • Microservices for IIoT data stored in noSQL database cluster
  • RESTful APIs for IIoT data sources
  • MES data and IIoT data can be combined for advanced analytic purposes
  • Message broker (e.g. Kafka, MQTT, CFX) for online streaming analytics
  • Real-time IT monitoring of MES components and related infrastructure
  • 24/7 system availability
  • MES exposes server and client health data via JMX interface
  • Monitoring module provides dashboard with bird's eye view and drill down capabilities
  • Rules can be configured for flexible alarming and notifications

CONTACT US

iTAC Software AG Sales
iTAC Software AG
Aubachstraße 24
56410 Montabaur
Germany
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