Production & Process Monitoring

Complete Production and Process Monitoring Capabilities

When you need to know everything that’s happening with your production activities and process variables, you need an MES that delivers the right functionality. From drag-and-drop job scheduling to real-time dashboard reporting and customizable alerts, PlantStar is designed to help you do what you do best. With a full range of capabilities and continuous updates, PlantStar has the solutions you and your company needs to maximize overall equipment effectiveness (OEE). It’s time to reach your full potential.

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MES Features

Get insight into job-specific details on every machine so you can keep track of upcoming projects, potential downtime, and more.

Job Scheduler

Job Scheduler

Simplify job scheduling with a drag-and-drop tool that makes it easy to move projects. The MES shows the current time and tools being used for specific projects, and allows you to update the tools and resources or switch the order of projects in order to avoid collisions.
Job Summary

Job Summary
The job summary screen gives you a quick, up-to-date picture of what is happening on any machine, even those that are not connected to this DCM. With the easy-to-use drop-down menu, you can quickly access important information on a desired machine and make changes to current and future jobs with a touch of the screen.
Job Setup Sheets

Job Setup Sheets
Easily access machine setup and miscellaneous summary information. Setup sheets can include training videos, documents, part images, and more.
Customizable Charts and Reporting

Customizable Charts and Reporting

Eliminate guesswork as you drive change and implement best practices as a result of data at your fingertips. PlantStar lets you create charts based on your own reporting in real time and auto-schedule report delivery directly to email inboxes, printer, or network folders.
Real-Time Dashboards

Real-Time Dashboards

View the status of your machines in real time on a large screen with color-coded data.
Downtime and Scrap Reporting

Downtime and Scrap Reporting

Get alerts when your machines go down and maintain a record of each occurrence. The system tracks the top causes of downtime for each machine and displays the percentage of time taken up by each down.
Instant Alerts

Instant Alerts

Receive immediate email, text, and voice alerts about the status of your machines on the shop floor. Easily choose which alerts you want to receive and select where you’d like them to be sent.
Defect Collection

Defect Collection
Conduct root-cause analysis to improve quality and eliminate warranty costs so you can reduce product recalls, revenue loss, decrease in customers, and damage to your brand. PlantStar prioritizes defects and charts them out in real time so you can immediately view all your defects for any running job or specific shift. Additional features include unlimited user configurable defect reasons, repair or scrap disposition, and ERP solutions integration.
Material and Tool Tracking

Material and Tool Tracking

See the status of materials used in specific machines so you know when the materials need to be replenished or the equipment needs maintenance. PlantStar’s extremely detailed data insight reduces the manual labor necessary to gather these details.

MES 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

Operator Tracking

Eliminate the guesswork in associating specific users with completed action events. With PlantStar 4.0 operator tracking, users can quickly identify operator action events using simple track-and-trace capabilities.
Labeling and Barcoding

Labeling and Barcoding

Reduce the percentage of recalls due to product label errors with labeling and barcoding capabilities that strengthen compliance, increase productivity, and reduce operating costs while focusing on product traceability.
ERP Integration

ERP Integration

Integrate PlantStar with your current ERP system to complete your manufacturing process management.
Remote Monitoring

Remote Monitoring

See the status of your production equipment wherever you are with remote monitoring functionality from any device connected to the internet.
Real-Time Data

Real-Time Data

Your machine operators need to be able to access timely data in order to make quick decisions, and PlantStar’s MES provides that and more. Get an up-to-date look at your most important metrics and KPIs on a single, customizable screen. With the Machine Status view, you have insight into the real-time status, efficiency, and production data for any machines you choose. Plus, you can access simplified, color-coded charting with historical and real-time process variable data.

Process Monitoring

Stay up to date about the variables that go into your projects, with the ability to easily make adjustments as necessary.

Physical or Trigger-Based Process Variables

Physical or Trigger-Based Process Variables

Some MES systems limit the user on the number of process variables, but with PlantStar you can input any number of PVs and process variable profiles.
Tailor Process Variable Limits

Tailor Process Variable Limits

Use PlantStar to set upper and lower limits to your process variables and easily adjust as production needs change.
Process Variable Chart Viewer

Process Variable Chart Viewer

View live readings of KPIs including pressure, temperature, and more in real time. Tweak the chart configuration on the fly for a truly granular view into the health of your machines.
Process Variable Table Viewer

Process Variable Table Viewer

Quickly view all the live readings for your process variables in table form to see if the thresholds you defined are being breached.

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