Production Monitoring | MES Solutions

Real-Time Insights for Smarter Manufacturing

In manufacturing, every second counts. Production monitoring is the cornerstone of ensuring that your operations run smoothly, efficiently, and with minimal waste. By capturing and analyzing production data in real time, manufacturers gain unparalleled visibility into machine performance, job progress, overall efficiency, and a huge impact in labor savings.

SYSCON PlantStar’s Manufacturing Execution System (MES) goes beyond basic monitoring. It provides a comprehensive platform to track key production metrics such as cycle time, output rates, and scrap percentages while integrating seamlessly with your existing ERP systems. With PlantStar’s production monitoring capabilities, you can transform your shop floor into a data-driven powerhouse, reducing costs and optimizing output.

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Why Production Monitoring Matters

Implementing a robust production monitoring solution unlocks transformative benefits for manufacturers:

Maximize Overall Equipment Effectiveness (OEE): Identify inefficiencies and maximize uptime by understanding how your equipment is performing in real-time. PlantStar automatically calculates your equipment Availability, Performance and Quality so your entire plants can see live OEE numbers.
Enhance Productivity: Track the status of every job and machine with live dashboards, intuitive reporting and end of shift reporting to stay ahead of schedule and under budget.
Reduce Scrap and Waste: Leverage detailed insights into reject rates and reasons, enabling proactive adjustments that improve yield.
Streamline Decision-Making: Access accurate, actionable data at a glance to empower your team to make faster, smarter decisions.

PlantStar’s MES is trusted across industries like medical, automotive, plastics, and consumer goods to deliver reliable performance and measurable results.

Production Monitoring Features

Overall Equipment Effectiveness (OEE)

Track and improve the true performance of your production assets. PlantStar automatically calculates OEE using availability, performance, and quality metrics, giving you clear insight into where downtime, slow cycles, or quality issues are impacting output. With accurate, real-time data, you can take quick action to maximize uptime and productivity.

Downtime and Scrap Analysis/Reporting

Get to the root of downtime and scrap with clear, visual reporting. PlantStar captures every downtime event and reject reason, organizing them into intuitive dashboards that highlight trends and recurring issues. These insights help your team eliminate inefficiencies, reduce waste, and keep machines running at peak performance.

Production Scheduling

Manage your production plan with ease. The drag-and-drop scheduler allows you to view and adjust jobs instantly across machines, shifts, or departments. As production progresses, schedules update automatically—keeping your team aligned, your resources optimized, and your orders on track.

Work order and Resource Management

Centralize and simplify your operations by connecting work orders, materials, tools, and personnel in one system. PlantStar tracks every element of a job from setup through completion, giving you visibility into resource utilization and helping you optimize labor, materials, and machine time for greater efficiency.

Quality Management and Traceability

Build quality into every stage of production. PlantStar collects detailed process and part data for complete traceability—ensuring every product meets your standards. Real-time SPC tools and automated email, text and voice alerts help your team catch deviations early, maintain compliance, and continuously improve process stability.

Integration with Enterprise Systems (ERP)

Seamlessly connect your MES and ERP systems for a unified flow of information. Import work orders and production schedules, export finished-goods data, and synchronize key metrics between the shop floor and back office. This two-way integration bridges data silos and keeps your entire operation working from the same real-time insights.

Production Monitoring Benefits

Take advantage of integration features, tracking capabilities, and a variety of other functionalities that help streamline your processes and deliver quality products.

Operator Tracking

Label Printing & Barcode Scanning

ERP Integration

Text to Voice Output

Remote Monitoring

End of Shift Reporting

Email & Text Alerts

Material Tracking & Forecasting

Tool Life Tracking

Tool Maintenance Events

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