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Modular MES++ Solutions

Connected Operations & IoT

Bridge the Gap Between Shop-Floor Operations and Top-Floor Planning

Is your production line a collection of isolated operations or a synchronized orchestra? Without a central nervous system to coordinate activities, even the most advanced machines and diligent workers can’t achieve peak performance. Our Modular MES++ Solutions serve as your factory’s digital command center, ensuring seamless data flow between IoT devices, MES, ERP, and SCM systems for unified operational intelligence and streamlined production. 

Modular MES++ Solutions

IoT Integration and Shop-Floor Automation
Implement comprehensive IoT integration to connect your entire manufacturing ecosystem. Our solutions bridge the gap between legacy equipment and modern systems through OPC UA and MQTT protocols, enabling real-time data acquisition from PLCs, CNCs, and sensors.
Technical Capabilities
  • Unified namespace architecture for seamless data integration
  • Industrial protocol conversion (OPC UA, MQTT, Modbus)
  • Edge analytics and real-time decision making
  • Automated workflow orchestration
ROI & Benefits
  • 40-50% reduction in manual data entry
  • 30-40% faster process execution
  • 99.5%+ data accuracy and availability
  • 25-35% reduction in integration costs
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Real-Time Asset Tracking and Monitoring
Deploy advanced asset management to maintain complete visibility of your manufacturing assets. Our solutions provide real-time tracking of equipment location, status, and utilization through RFID, and IoT sensors, integrated with your MES for comprehensive asset lifecycle management.
Technical Capabilities
  • Real-time location systems (RTLS) for tools and equipment
  • Digital twin integration for asset visualization
  • Predictive analytics for asset performance
  • Automated maintenance scheduling
ROI & Benefits
  • 25-30% faster asset retrieval times
  • 10-20% improvement in asset utilization
  • 15-25% reduction in capital expenditures
  • 99%+ asset availability
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Predictive Maintenance
Transform your maintenance operations from reactive to predictive using our AI-powered solutions that can analyze equipment sensor data, maintenance history, and operational parameters to forecast failures before they occur, enabling proactive maintenance scheduling and minimizing unplanned downtime.
Technical Capabilities
  • Machine learning models for failure prediction
  • Vibration analysis and thermal monitoring
  • Remaining useful life (RUL) estimation
  • Automated work order generation
ROI & Benefits
  • 20-30% reduction in unplanned downtime
  • 15-25% extension in asset lifespan
  • 30-40% reduction in maintenance costs
  • 95%+ maintenance schedule adherence
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Energy Management and Optimization

In partnership with TOR.ai, we deliver comprehensive energy monitoring and optimization solutions through the Tor Shield Energy platform. TOR.ai specializes in industrial IoT and energy intelligence, providing the secure, certified infrastructure that powers our energy management offerings. Together, we enable complete visibility and control over your plant’s energy footprint.

Gain a drill-down view of total energy consumption to identify which loads consume the most power and direct energy-saving initiatives that reduce overall costs.

Technical Capabilities
  • Single-line diagram view for granular plant-wide energy monitoring
  • Patented analytics engine to prioritize energy abnormalities
  • Remote load management with central ON/OFF control
  • Machine, line, shop, and plant-level specific energy consumption correlation
  • Customizable dashboards with real-time KPI management
  • Comprehensive monitoring of voltages, currents, power factors, and energy parameters
  • Branch operation comparison to identify top and bottom performing divisions
  • ERP system integration for seamless data flow
  • Real-time alerts via email and WhatsApp with performance thresholding
ROI & Benefits
  • Complete electricity bill reconciliation and cost allocation
  • Prioritized energy efficiency initiative tracking with measurable ROI
  • 10-15% reduction in energy consumption through targeted optimization
  • 20-25% lower energy costs via load management and efficiency improvements
  • 30-40% faster energy anomaly detection and response
  • Centralized control of distributed energy loads
  • Compliance with sustainability targets and regulatory requirements
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Quality Control and Assurance
Integrate comprehensive quality management through our modular solutions to embed quality directly into your manufacturing processes. Our solutions enable statistical process control (SPC), automated inspection, and real-time quality analytics, ensuring consistent quality standards throughout production.
Technical Capabilities
  • Real-time SPC and automated control chart monitoring
  • AI-powered defect detection and classification systems
  • Non-contact measurement and vision inspection capabilities
  • Closed-loop quality control with automatic process adjustment
ROI & Benefits
  • 15-25% reduction in quality-related rework
  • 40-50% faster defect detection and resolution
  • 99.7%+ first-pass yield rates
  • 30-40% reduction in quality costs and warranty claims
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Implementation and Integration

Our Modular MES++ Solutions built on our I4Verse Platform, ensure seamless integration with your existing ERP (SAP, Oracle), PLM, and SCM systems. We deploy using containerized microservices on Kubernetes platforms, providing scalability, flexibility, and future-proof architecture.

Technologies
  • Siemens Opcenter
  • PTC ThingWorx
  • Rockwell FactoryTalk
  • AWS IoT
  • Azure ML
  • OSIsoft PI
Quantifiable Outcomes:
  • 20-30% improvement in overall equipment effectiveness
  • 25-35% reduction in unplanned downtime
  • 40-50% faster decision-making
  • 99.5%+ data accuracy across systems
  • 15-25% increase in production throughput
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Stop managing your factory in the dark. Implement Actin's Modular MES++ Solutions and transform your operations into a responsive, data-driven powerhouse.

Let’s discuss your specific sector challenges and digital opportunities. 

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