MES Module

Manufacturing Execution System with real-time CNC monitoring, OEE reporting, shift-based analytics, and production run tracking.

Base URL: https://app.proign.com/[tenant]/mes/api

Overview

The MES module connects to CNC machines via MTConnect to provide real-time production visibility across your entire shop floor:

Live machine status monitoring with sub-second updates
OEE (Overall Equipment Effectiveness) calculation per machine and aggregate
Alarm tracking, categorization, and notifications
Production run analytics with cycle time breakdowns
Shift-based reporting and machine utilization metrics
Historical data retention with configurable policies

MTConnect Configuration

Machines communicate with the MES module through the MTConnect standard. Each CNC machine runs an MTConnect adapter that translates machine-native data into a standardized XML format. An MTConnect agent aggregates data from one or more adapters and exposes it over HTTP.

Adapter Setup

The adapter runs on or near the CNC controller and maps internal signals (FANUC FOCAS, Siemens OPC-UA, Haas MDC, etc.) to MTConnect data items. A typical adapter configuration:

# adapter.cfg — runs on the machine controller
host = 0.0.0.0
port = 7878
machine_id = HAAS-VF2-001

# Data items mapped from controller registers
[data_items]
spindle_speed    = R100   # RPM
feed_rate        = R101   # mm/min
execution_state  = R200   # ACTIVE | IDLE | STOPPED
emergency_stop   = R201   # TRIGGERED | ARMED
program_name     = R300   # Current G-code program
part_count       = R400   # Parts completed this cycle

Agent Configuration

The MTConnect agent collects data from all adapters on the shop floor and provides a single HTTP endpoint that the MES module polls:

# agent.cfg
Devices = ./devices.xml
Port = 5000
BufferSize = 131072
CheckpointFrequency = 1000

Adapters {
  HAAS-VF2-001 {
    Host = 192.168.1.101
    Port = 7878
  }
  HAAS-VF2-002 {
    Host = 192.168.1.102
    Port = 7878
  }
  DMG-NLX-2500 {
    Host = 192.168.1.103
    Port = 7878
  }
}

Data Items

The MES module tracks the following MTConnect data item categories:

Samples — Numeric values: spindle speed, feed rate, axis positions, spindle load, temperatures
Events — State changes: execution state, controller mode, program name, tool ID, part count
Conditions — Machine health: alarms, warnings, faults with severity and native code

Registering a Machine

After the adapter and agent are running, register the machine with the MES module so it begins collecting data:

POST /api/[tenant]/mes/machines
Content-Type: application/json

{
  "name": "Haas VF-2 #001",
  "machine_id": "HAAS-VF2-001",
  "agent_url": "http://192.168.1.10:5000",
  "type": "milling",
  "location": "Bay A, Position 3",
  "poll_interval_ms": 1000
}

Key Features

Machine Monitoring

Real-time status for all connected CNC machines:

Status — Active, idle, alarm, offline
Spindle — Speed (RPM), load (%), override (%)
Feeds — Feed rate (mm/min), rapid override (%)
Program — Current program name, block number, line
Axes — X, Y, Z positions and work offsets
Tool — Active tool ID, tool life remaining

OEE Formula

Overall Equipment Effectiveness is the gold standard for measuring manufacturing productivity. The MES module calculates OEE automatically from machine data using three components:

OEE = Availability x Performance x Quality

Availability — Was the machine running when scheduled?

(Planned Production Time - Downtime) / Planned Production Time

Downtime includes unplanned stops (alarms, breakdowns) and planned stops (setup, changeover). Shift schedules define planned production time.

Performance — Was the machine running at full speed?

(Ideal Cycle Time x Total Parts Produced) / Run Time

Accounts for slow cycles, micro-stops, and reduced feed rates. The ideal cycle time is set per part program.

Quality — Were all parts good?

Good Parts / Total Parts Produced

Rejected parts and rework count against quality. Parts can be marked as rejected via the API or operator interface.

World-class OEE is considered to be 85% or higher. The MES module provides per-machine and aggregate OEE with configurable date ranges, shift filters, and trend comparisons.

Real-time OEE — Updates every polling interval based on the current shift
Historical OEE — Daily, weekly, monthly rollups with trend lines
Benchmarks — Compare machines, shifts, or time periods side by side

Shift Definitions

Shifts define the planned production windows used in OEE calculations and reporting. Each tenant configures their own shift schedule:

POST /api/[tenant]/mes/shifts
Content-Type: application/json

{
  "shifts": [
    {
      "name": "First Shift",
      "start": "06:00",
      "end": "14:00",
      "break_minutes": 30,
      "days": ["mon", "tue", "wed", "thu", "fri"]
    },
    {
      "name": "Second Shift",
      "start": "14:00",
      "end": "22:00",
      "break_minutes": 30,
      "days": ["mon", "tue", "wed", "thu", "fri"]
    },
    {
      "name": "Third Shift",
      "start": "22:00",
      "end": "06:00",
      "break_minutes": 30,
      "days": ["mon", "tue", "wed", "thu", "fri"]
    }
  ]
}

Shift-based reporting provides:

Per-shift OEE — Compare productivity across first, second, and third shifts
Shift handoff reports — Automatically generated at shift boundaries with machine status summaries
Break deduction — Break minutes are excluded from planned production time in OEE calculations
Overnight shifts — Shifts that cross midnight (like third shift) are handled correctly

Alarm Codes

The MES module captures and categorizes CNC alarms from MTConnect condition data items. Alarms are classified by category and severity:

Alarm Categories

Emergency Stop — Operator or safety-triggered E-stop. Machine halts all motion immediately. Requires manual reset.
Axis Errors — Position deviation, servo overload, or encoder faults on X, Y, Z, or rotary axes. Often indicates mechanical issues or collision.
Spindle Alarms — Spindle overload, overheating, or orientation failure. May indicate tool breakage or excessive cutting parameters.
Tool Change — ATC (Automatic Tool Changer) errors, tool not found, magazine position faults, or tool breakage detection.
Hydraulic / Pneumatic — Low pressure, filter clogged, or coolant system faults.
Communication — Loss of connection to adapter, agent timeout, or network errors.

Severity Levels

CRITICAL  — Machine stopped, immediate attention required (E-stop, servo fault)
WARNING   — Degraded operation, machine may continue (high spindle load, temp warning)
INFO      — Advisory condition, no action needed (tool life low, filter reminder)

Alarms trigger downtime tracking automatically. The time between alarm onset and clearance is recorded as unplanned downtime and reduces the Availability component of OEE.

Production Runs

A production run represents a batch of parts being manufactured on a specific machine. Runs are tracked from start to completion and provide the foundation for cycle time analysis:

Run Lifecycle

setup → running → paused → running → completed

Starting a Run

POST /api/[tenant]/mes/runs
Content-Type: application/json

{
  "machine_id": "HAAS-VF2-001",
  "job_number": "JOB-2026-0145",
  "part_number": "PN-4820",
  "program_name": "O0145",
  "planned_quantity": 500,
  "ideal_cycle_time_sec": 42
}

Cycle Time Analysis

During a production run, the MES module tracks individual cycle times based on the part count data item from MTConnect:

Ideal cycle time — The target time per part, set when the run is created
Actual cycle time — Measured time between consecutive part count increments
Average cycle time — Running average across all completed parts in the run
Cycle time distribution — Histogram showing variance to identify outliers and slow cycles

Runs also track reject counts, operator notes, and setup time separately from production time for accurate OEE calculations.

API Endpoints

Machines

GET    /api/[tenant]/mes/machines            # List all machines
POST   /api/[tenant]/mes/machines            # Register a new machine
GET    /api/[tenant]/mes/machines/[id]       # Get machine details
PATCH  /api/[tenant]/mes/machines/[id]       # Update machine config
GET    /api/[tenant]/mes/machines/[id]/status # Live machine status

OEE

GET    /api/[tenant]/mes/oee                 # Aggregate OEE summary
GET    /api/[tenant]/mes/oee/[machineId]     # Per-machine OEE
GET    /api/[tenant]/mes/oee/history         # Historical OEE data

Alarms

GET    /api/[tenant]/mes/alarms              # List active alarms
GET    /api/[tenant]/mes/alarms/history      # Alarm history with filters
POST   /api/[tenant]/mes/alarms/[id]/ack     # Acknowledge an alarm

Production Runs

GET    /api/[tenant]/mes/runs                # List production runs
POST   /api/[tenant]/mes/runs                # Start a new run
GET    /api/[tenant]/mes/runs/[id]           # Get run details
PATCH  /api/[tenant]/mes/runs/[id]           # Update run (pause, resume, complete)
GET    /api/[tenant]/mes/runs/[id]/cycles    # Cycle time data for a run

Shifts

GET    /api/[tenant]/mes/shifts              # Get shift schedule
POST   /api/[tenant]/mes/shifts              # Create/update shift schedule
GET    /api/[tenant]/mes/shifts/current      # Get current active shift

Request Examples

Query Machine Status

GET /api/[tenant]/mes/machines/HAAS-VF2-001/status
Authorization: Bearer <token>

Response:

{
  "data": {
    "machine_id": "HAAS-VF2-001",
    "name": "Haas VF-2 #001",
    "status": "ACTIVE",
    "last_updated": "2026-02-21T14:32:01Z",
    "spindle": {
      "speed_rpm": 8500,
      "load_pct": 34,
      "override_pct": 100
    },
    "feed": {
      "rate_mm_min": 2400,
      "override_pct": 100
    },
    "program": {
      "name": "O0145",
      "block": "N1240",
      "comment": "FINISH PASS OD"
    },
    "axes": {
      "x": -45.230,
      "y": 12.005,
      "z": -85.100
    },
    "active_tool": {
      "id": "T12",
      "life_remaining_pct": 72
    },
    "current_run": {
      "id": "run_abc123",
      "job_number": "JOB-2026-0145",
      "parts_completed": 312,
      "planned_quantity": 500
    }
  }
}

Query OEE with Filters

GET /api/[tenant]/mes/oee/HAAS-VF2-001?from=2026-02-01&to=2026-02-21&shift=First+Shift
Authorization: Bearer <token>

Response:

{
  "data": {
    "machine_id": "HAAS-VF2-001",
    "period": {
      "from": "2026-02-01T00:00:00Z",
      "to": "2026-02-21T23:59:59Z"
    },
    "shift": "First Shift",
    "oee": 0.782,
    "availability": 0.91,
    "performance": 0.88,
    "quality": 0.976,
    "details": {
      "planned_time_min": 9600,
      "run_time_min": 8736,
      "downtime_min": 864,
      "total_parts": 12480,
      "good_parts": 12181,
      "rejected_parts": 299,
      "ideal_cycle_time_sec": 42,
      "avg_cycle_time_sec": 47.8
    }
  }
}

Complete a Production Run

PATCH /api/[tenant]/mes/runs/run_abc123
Content-Type: application/json
Authorization: Bearer <token>

{
  "status": "completed",
  "actual_quantity": 500,
  "rejected_quantity": 8,
  "operator_notes": "Tool T12 replaced at part 290, slight chatter on finish pass"
}

Data Retention

The MES module stores different data types with different retention periods. Raw high-frequency data is downsampled over time while aggregated metrics are kept long-term:

Raw machine samples (spindle speed, feed rate, axis positions) — 30 days at full resolution, then downsampled to 1-minute averages
Machine events (status changes, program changes, tool changes) — 90 days at full detail
Alarm history — 1 year with full context (native code, severity, duration, resolution)
OEE rollups (hourly, daily, weekly, monthly) — 2 years
Production run records — 2 years including cycle time distributions
Shift reports — 2 years

Retention policies can be adjusted per tenant. Data approaching its retention limit is automatically archived before deletion.

Analytics Module

Build dashboards and reports from MES data

Events Module

Subscribe to machine status changes and alarm notifications

MES Module

Overview

MTConnect Configuration

Adapter Setup

Agent Configuration

Data Items

Registering a Machine

Key Features

Machine Monitoring

OEE Formula

Shift Definitions

Alarm Codes

Alarm Categories

Severity Levels

Production Runs

Run Lifecycle

Starting a Run

Cycle Time Analysis

API Endpoints

Machines

OEE

Alarms

Production Runs

Shifts

Request Examples

Query Machine Status

Query OEE with Filters

Complete a Production Run

Data Retention

Related

Analytics Module

Events Module