Process Monitoring | MES Solutions

Process Monitoring: Elevate Your Manufacturing Efficiency

In today’s fast-paced manufacturing environment, precision and efficiency are more critical than ever. Process monitoring is the key to maintaining control over every aspect of your production. By capturing and analyzing real-time process data, manufacturers gain the insights they need to ensure consistency, reduce downtime, and optimize resource utilization.

SYSCON PlantStar's Manufacturing Execution System (MES) transforms raw data into actionable intelligence. From tracking critical process variables like temperature, pressure, and cycle time, to identifying trends with Statistical Process Control (SPC), PlantStar empowers your team to make proactive decisions that enhance quality and productivity. Whether you're producing medical devices, automotive components, or consumer goods, our solutions adapt to your unique needs, helping you achieve operational excellence.

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Unlock the Benefits of Real-Time Process Monitoring

Implementing process monitoring with PlantStar brings measurable advantages to your production floor:

Improved Quality: Monitor process variables in real time to detect deviations before they impact product integrity, reducing defects and waste.
Enhanced Efficiency: Gain visibility into machine health and performance, allowing you to optimize settings and minimize downtime.
Cost Reduction: Streamline operations with predictive analytics and automated alerts, cutting expenses associated with rework, scrap, and equipment failures.
Actionable Insights: Turn data into decisions with intuitive dashboards, custom reports, and SPC tools that put control in your hands.

With over 50 years of experience and a proven track record across industries like medical, automotive, and plastics, SYSCON PlantStar is your trusted partner in manufacturing innovation.

Process Monitoring Features

Monitor and Control Equipment and Processes

Gain total command of your manufacturing floor. PlantStar continuously monitors key machine and process parameters, providing operators and managers with real-time insight and control. By automating data collection and feedback, you can ensure every machine operates within defined specifications—minimizing variability, improving performance, and maintaining consistent quality across every run.

Thresholds and Instant Alerts

Stay one step ahead of process deviations. PlantStar’s configurable thresholds trigger instant alerts when any variable moves outside of optimal limits. Notifications can be sent by text, email, or displayed directly on dashboards, ensuring your team responds immediately to prevent equipment issues, reduce downtime, and protect product integrity.

Statistical Process Control (SPC)

Turn data into continuous improvement. PlantStar’s integrated SPC tools visualize and analyze process data in real time, helping you detect trends, predict deviations, and keep production within tolerance. With interactive charts and control limits, your team can identify root causes faster and maintain precision at every stage of manufacturing.

Inventory Management and Material Tracking (Recipe Management)

Streamline material usage and ensure batch consistency. PlantStar links material data and machine parameters through recipe management, allowing you to standardize production runs and trace every input. From raw material to finished part, the system tracks consumption, lot numbers, and setup conditions for complete traceability and simplified compliance.

Process Variable Overlay

Reveal deeper insights into your production data. The Process Variable Overlay feature allows you to view multiple process variables—such as temperature, pressure, and injection speed—on a single, easy-to-read chart. By comparing variable relationships, you can uncover patterns, optimize performance, and enhance overall process stability.

Process Variable Dashboards

See your entire operation at a glance. PlantStar’s customizable dashboards provide a clear, visual representation of live process data, organized by machine, shift, or product line. With intuitive charts and color-coded indicators, you can quickly identify trends, verify performance, and make data-driven decisions that improve efficiency and product quality.

See The Benefits of Robust MES Software

Could your manufacturing operation benefit from more data? With a robust Manufacturing Execution System (MES), you can combine Production & Process Monitoring to improve productivity and ensure quality and efficiency.

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What Our Customers Say

We chose SYSCON PlantStar to be our MES system as it provided us with a wealth of production and process information, including scheduling, product specification, OEE data, labor and process tracking in a flexible, friendly and real time environment that assist us in achieving our operational excellence goals. Over the years (20+ years) PlantStar had validated that we made the right decision by providing us with great customer service and support coupled with leading edge technology. I would highly recommend their services to any other company that is in the market for MES system

Fourmark Manufacturing

With PlantStar, we’ve reduced our internal and external corrective action reports by 92.8%, with major gains in first-time quality improvements and customer satisfaction. An initial savings of $400,000 was realized within five months of implementation.

Corporate VP, Tier II Automotive Supplier

PlantStar has proved vital to our Manufacturing efficiency and has introduced the ability to stay connected remotely to make key real-time decisions. It has changed the way we operate!

Cole Melton, Director of Operations

Process Monitoring: Elevate Your Manufacturing Efficiency

Unlock the Benefits of Real-Time Process Monitoring

Process Monitoring Features

See The Benefits of Robust MES Software

What Our Customers Say

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