+ 90 850 305 1220 | info@roltek.com.tr
FAST IoT Platform · Manufacturing Execution System
Keep your production line's pulse remotely
Monitor machine downtime, production counts, OEE and line-level energy consumption on a single platform. Manage production in real time without replacing your existing PLCs and meters or going on-site.
24/7
Real-time production monitoring
±5 sec
Downtime detection delay
%OEE
Automatic calculation
⚙️
LINE 1
Running
⚙️
LINE 2
Waiting
🛑
LINE 3
Down
⚙️
LINE 4
Running
Overall Equipment Effectiveness (OEE) — Today
🏭 Line 1 — Injection Molding AProducing
🏭 Line 2 — Assembly Line BMold Change
🏭 Line 3 — Packaging UnitDown
🏭 Line 4 — CNC Machining CenterProducing
Features
Everything you need for manufacturing execution
An end-to-end MES solution built on the FAST IoT Platform, collecting data from your PLCs and field equipment.
OEE Tracking
Overall Equipment Effectiveness (OEE), made up of availability, performance and quality rates, is calculated automatically. Compare results by line, shift and machine.
Availability · Performance · Quality
Downtime & Andon Management
Unplanned stops are detected instantly and their reasons (breakdown, waiting for material, mold change) are coded by the operator. The team is alerted immediately via the andon screen and SMS/email.
Downtime reason coding · Instant andon alert
Production Counting & Traceability
Real-time production count via line output, box counter or PLC signal. Batch and lot-level traceability is provided for retrospective analysis.
Pulse counter · PLC integration · Lot tracking
Line-Level Energy Consumption
Each machine's or line's energy consumption is tracked separately. Energy cost per unit produced is calculated, and inefficient equipment is identified.
kWh / unit · Modbus meter integration
Quality & Rejection Tracking
Rejects/scrap counts and reasons on the production line are logged. Quality rate is calculated in real time, and recurring defect sources are reported.
Scrap reason coding · Quality rate reporting
Hierarchical Plant Structure
A Plant → Line → Machine → Station drill-down structure. Manage multiple facilities and shifts from a single platform, with role-based access control included.
Unlimited lines/machines · Role-based access
Shift & Production Plan Comparison
Planned production volume is automatically compared against actual output. Efficiency and target deviation are reported by shift.
Plan vs. actual · Shift reporting
Maintenance Alerts (Predictive Maintenance)
Periodic maintenance reminders are automatically generated based on running hours, cycle count or vibration thresholds. Unexpected breakdowns are reduced.
Running-hour tracking · Maintenance reminders
Centralized Reporting
Shift, daily, weekly and monthly production reports are generated automatically and sent to the relevant people in Excel/PDF format on a schedule.
Excel / PDF · Scheduled report delivery
System Architecture
Compatible with your existing PLCs and site
📡 Field Data Collection
ProtocolsModbus RTU/TCP · OPC UA · Digital I/O · 4-20mA
Communication4G/LTE · LoRaWAN · RS-485 · Ethernet
HardwareRoltek IoT Gateway & Industrial Router
PLC CompatibilityBrand-independent
Meter IntegrationElectricity / gas / air meters
📶 FAST IoT Platform
DashboardCustomizable · Drag-and-drop widgets
OEE EngineAutomatic calculation · Target-based comparison
Alarm SystemThreshold-based · SMS & email notification
Rule EngineAutomatic triggers & action definitions
APIREST API · MQTT protocol
AccessWeb & mobile · Role-based authorization
Platform Preview
Production data on a single screen
Monitor line status in real time, track downtime reasons, and review OEE and production reports.
MES · Line Status
4 lines monitored · Last update: 6s ago
| Line | Product | Status | Current Speed | Shift Count | OEE |
|---|---|---|---|---|---|
| Line 1 | Body Injection | Producing | 42 pcs/min | 3,140 | 89% |
| Line 2 | Assembly — Model B | Mold Change | — | 1,860 | 61% |
| Line 3 | Packaging | Down | 0 pcs/min | 2,410 | 44% |
| Line 4 | CNC Machining | Producing | 18 pcs/min | 980 | 93% |
Deployment
Live in 4 steps
1
Site Survey
Existing PLC, meter and sensor infrastructure is reviewed. The data points to collect and the communication method are determined.
2
Hardware Installation
The Roltek IoT gateway is mounted inside the panel and connected to your PLC via Modbus, digital I/O or 4-20mA signals. Installation is done without stopping production.
3
Platform Configuration
Line hierarchy, OEE targets, downtime codes and alarm thresholds are defined on the FAST IoT Platform.
4
Go-Live
Operator and manager screens are activated and the team is trained. The system goes live with 24/7 monitoring.
What Is MES (Manufacturing Execution System)?
A Manufacturing Execution System (MES) is a software-hardware solution that collects, monitors, analyzes and manages machine, operator and process data on the production line in real time. It bridges the data gap between ERP and shop-floor equipment.
Roltek's MES solution collects data from your existing PLCs via IoT gateways and industrial routers, and brings together OEE, downtime, quality and energy data on a single screen within the FAST IoT Platform. There is no need to replace your existing automation infrastructure.
What Problems Does It Solve?
- → Unplanned stops being noticed too late, resulting in lost production time
- → OEE, efficiency and quality rates being calculated manually and with delay
- → Production and scrap data not being transparently comparable across shifts
- → Lack of visibility into line/machine-level energy consumption and unit cost
- → Maintenance needs not being noticed until a breakdown occurs
- → Production reports being compiled manually in Excel
Use Cases
Which production environments use it?
MES needs vary by production type. Explore our solutions configured specifically for each type of facility.
Automotive Supply Industry
Line and cycle time tracking
Cycle time, OEE and scrap tracking on injection, welding and assembly lines. Traceability data ready for supplier audits.
Early detection of cycle time deviation
Analysis of mold change durations
🔧 PLC INTEGRATION · OEE
Food & Beverage Production
Hygiene and batch tracking
Production counting on filling lines, batch/lot-level traceability, and integrated monitoring of critical temperature/humidity points.
Lot-level retrospective traceability
Scrap and rejection rate analysis
📦 LOT TRACKING · FOOD SAFETY
Metal & Plastics Processing
CNC and injection machines
Cycle, downtime and maintenance data collected from CNC machining centers and injection molding machines to plan predictive maintenance.
Machine-level efficiency comparison
Reduced breakdowns via predictive maintenance
⚙️ CNC · INJECTION · MAINTENANCE
Contact
Request a demo,
let's evaluate your production line together
Let us prepare a presentation tailored to your existing PLC and field infrastructure. Our team will get in touch with you shortly.
Phone+90 850 305 1220
Emailsatis@roltek.com.tr
Addressİzmir, Türkiye
Request a Demo
FAQ
Frequently asked questions
