We connect your Manufacturing Execution System to the rest of the plant — ERP, PLCs, SCADA, historians, and IIoT platforms — so work orders, machine data, and production results flow in real time instead of living in silos.
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A Manufacturing Execution System only delivers value when it is connected — upward to ERP for work orders, BOMs, and production confirmations, and downward to PLCs, SCADA, historians, and IIoT platforms for the real-time machine and line data that drives execution. On its own, an MES is another island; integrated, it becomes the live bridge between the business and the shop floor.
The hard part is not the MES API — it is the plant. Every site runs a different mix of controllers, protocols, and vendor tag conventions, and shop-floor data arrives far faster than ERP can consume it. We build a protocol-aware integration layer (OPC UA, MQTT, Modbus, MTConnect) that normalizes equipment data onto an ISA-95 model, buffers high-frequency signals, and keeps MES, ERP, quality, and warehouse systems synchronized on one consistent picture.
See how we design MES integration — ERP synchronization, machine connectivity, and a normalization layer that survives a real multi-vendor plant.
Common failure modes
Challenge
Every plant runs a different mix of PLCs, historians, and ERP.
Agnotic approach
We profile the real equipment and system inventory per site and build a protocol-aware layer (OPC UA, MQTT, Modbus, MTConnect) instead of brittle point-to-point glue.
Challenge
Shop-floor data arrives faster than ERP can consume it.
Agnotic approach
A buffering and aggregation layer summarizes high-frequency machine signals into the batch, order, and confirmation events ERP actually needs.
Challenge
Machine and line data uses vendor-specific tags and units.
Agnotic approach
A tag-normalization and unit-mapping layer maps raw signals onto a canonical ISA-95 equipment hierarchy before anything downstream reads them.
Challenge
Integrations fail silently and stall production visibility.
Agnotic approach
Store-and-forward queues, health checks, and alerting so a dropped connection is caught and recovered, not turned into a blind spot on the floor.
The exact connectivity surface behind a Manufacturing Execution System that talks to the whole plant.
Bi-directional MES↔ERP for work orders, BOMs, materials, and production confirmations across SAP, Oracle, and Microsoft Dynamics.
OPC UA, Modbus, and MTConnect connectors that pull real-time machine, sensor, and line data from PLCs, SCADA, and historians.
IIoT platform and time-series historian integration over MQTT so equipment telemetry feeds dashboards, analytics, and predictive models.
ISA-95 / B2MML data models and API integration so MES, ERP, quality, and warehouse systems exchange one consistent, coded picture.
Where it runs
Push work orders and BOMs down; return production confirmations, scrap, and consumption up to ERP.
Stream machine and line status onto live dashboards so supervisors see the floor as it runs.
Turn raw machine signals into availability, performance, and quality metrics with captured downtime reasons.
Link materials, machines, and operators to each unit for full forward and backward traceability.
Feed in-line inspection and lab results into MES to gate releases and trigger holds automatically.
Keep MES material movements aligned with WMS and ERP inventory in real time.
MES projects break on protocol variance and data volume, not on the MES API. We plan for both from the first site survey.
Standards we build against
Equipment survey, protocol mapping, and monitoring treated as the real engineering — not an afterthought.
We inventory the real equipment, controllers, historians, and ERP surface per site and map which protocols and tags actually appear.
We stand up OPC UA / MQTT / MTConnect connectors and map raw signals onto an ISA-95 canonical model and your ERP objects.
We validate flows against real machine data and edge cases — dropped connections, out-of-order signals, and burst loads.
Cutover with store-and-forward queues, health checks, and alerting so operations can see and recover any dropped feed.
Integration surface
The systems an integrated MES connects to and how we handle each.
| System | Typical protocol | Direction | What flows |
|---|---|---|---|
| ERP (SAP / Oracle / Dynamics) | REST / IDoc / BAPI | Round-trip | Work orders, BOMs, materials down; confirmations, scrap, consumption up. |
| PLC / SCADA | OPC UA / Modbus | Inbound | Real-time machine state, counts, and process values. |
| Machine tools | MTConnect | Inbound | Spindle, cycle, and utilization data from CNC and tooling. |
| IIoT platform / historian | MQTT / time-series | Round-trip | Telemetry for dashboards, analytics, and predictive models. |
| Quality / LIMS | REST / file | Round-trip | Inspection and lab results that gate releases and holds. |
Every plant differs. We profile your actual equipment and system inventory before committing to a mapping.
Real plant connectivity that stays operable — not an isolated demo interface.
Store-and-forward buffering and audited data movement so plant data is never silently lost between systems.
Fluent in ISA-95, OPC UA, MQTT, and the PLC / SCADA / historian stack — not just enterprise REST APIs.
Engineered for high-frequency shop-floor data without overwhelming ERP or the network.
We connect MES to ERP, IIoT, quality, and analytics as one system, rather than shipping isolated point interfaces.
Connected manufacturing operations, done right
Send us your equipment and system inventory. We will return a realistic MES integration plan with protocols, mapping, and monitoring.
contact@agnotic.com
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