Enterprise Manufacturing Execution System (MES & MSM) Specification
NavMSM by 92Technology is an enterprise multi-tenant Manufacturing Management Platform (MSM) and Execution System (MES). Engineered for process and discrete manufacturing plants, NavMSM provides comprehensive operational governance across 22 modular domains—from product lifecycle management (PLM) and multi-level BOMs to finite capacity scheduling (MPS/MRP), shop floor touchscreen kiosks, and industrial IoT machine telemetry.
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Detailed Breakdown of All 22 NavMSM Modules
Explore every module in sequence, engineered for high performance, enterprise data integrity, and intuitive day-to-day usability:
Platform Core 1. Tenant & Subscription Management
Industrial multi-tenant foundation providing isolated manufacturing factory workspaces, tenant branding, and license governance:
- Tenant Provisioning: Automated onboarding, dedicated production databases, and initial factory setup wizards.
- Subscription & Usage Metering: Metered license tiers based on active machine terminals, users, and factories.
- Data Security Isolation: Row-level cryptographic tenant scoping protecting proprietary engineering formulations.
- Custom Industrial Branding: Tailored factory branding, localized shift calendars, and unit-of-measure conventions.
Engineering 2. Product Lifecycle Management (PLM)
Central engineering repository governing product revisions, technical specifications, and formal change requests:
- Product Master Data: Detailed engineering specifications, drawings, variant parameters, and CAD attachments.
- Engineering Change Orders (ECO): Formal change request approval routing with automated impact analysis on active BOMs.
- Strict Revision Control: Historical audit trail of revisions ensuring factory floors always manufacture to latest specs.
- Part Obsolescence Tracking: Proactive alerts flagging phased-out raw components before production schedules are locked.
Product Recipes 3. Bill of Materials (BOM) & Routing Management
Multi-level hierarchical engineering recipe builder defining components, routing sequences, and work center setups:
- Multi-Tier Indented BOMs: Deep parent-child component hierarchies from raw materials to sub-assemblies and final goods.
- Yield & Scrap Factors: Account for scrap percentages and evaporation losses to ensure accurate raw material calculations.
- Routing Operation Steps: Define sequence of shop-floor operations (Cutting, Machining, Welding, Assembly, Painting).
- Work Center Hourly Rates: Allocate machine hourly rates, direct labor costs, and setup times for accurate cost rollups.
Master Scheduling 4. Production Planning & Scheduling (MPS)
High-level master scheduling balancing customer sales demand against plant capacity constraints and material availability:
- Master Production Schedule (MPS): Weekly and monthly production targets derived from sales orders and forecasts.
- Finite Capacity Planning: Algorithmic scheduling considering machine constraints, tooling, and labor shift limits.
- Interactive Production Gantt: Visual drag-and-drop scheduling board allowing production managers to resequence jobs.
- Bottleneck Identification: Automatically detect overloaded machine work centers and suggest alternative routings.
Material Planning 5. Material Requirements Planning (MRP I & II)
Automated material requirements calculation determining exactly what raw materials to purchase and when:
- Automated BOM Explosion: Explodes master schedules into precise gross component requirements.
- Net Requirements Calculation: Factors in on-hand inventory, in-transit purchase orders, and existing reservations.
- Lead-Time Offsetting: Factors supplier lead times to recommend precise purchase order issuance dates.
- Actionable Shortage Warnings: Immediate alerts highlighting raw material shortages that could halt production lines.
Shop Floor MES 6. Shop Floor Control & Manufacturing Execution (MES)
Real-time operational execution console connecting plant managers with operators on the factory shop floor:
- Digital Work Orders & Job Cards: Automated work order generation complete with QR-coded traveler documents.
- Shop Floor Touchscreen Kiosks: Rugged terminal interfaces for operators to start jobs, record pauses, and log output.
- Real-Time Operation Dispatching: Push prioritized work queues directly to specific machines and workstations.
- In-Process Scrap & Downtime Logging: Operators log exact machine downtime causes (Breakdown, Tooling, Material).
Quality Control 7. Quality Management & SPC Inspection (QMS)
Rigorous quality assurance enforcing standardized inspection plans, statistical process control, and defect investigations:
- Multi-Stage Inspection Gates: Mandatory QC inspection points at Raw Material Receipt, First-Piece, and Final Inspection.
- Statistical Process Control (SPC): Real-time X-bar and R control charts detecting manufacturing drift before defects occur.
- Non-Conformance Reporting (NCR): Quarantine defective batches with photographic evidence and disposition routing.
- Corrective & Preventive Action (CAPA): Structured 8D and 5-Why root-cause investigation workflows.
Warehouse Logistics 8. Raw Material & Finished Goods Warehousing
Factory warehouse management managing raw material staging bays, WIP buffers, and finished goods distribution:
- Location & Bin Mapping: Manage raw material racks, chemical drums, staging bays, and finished goods pallets.
- Traceable Batch & Lot Control: Full upstream and downstream lot genealogy linking finished goods back to supplier coils.
- FEFO / FIFO Picking Rules: Enforce First-Expired-First-Out picking logic for perishable chemicals and raw resins.
- Shop-Floor Material Requisitions: Automated issuance of raw materials from stores to active work orders.
Procurement 9. Procurement & Supplier Portal
Industrial procurement handling specialized raw materials, packaging supplies, and supplier delivery coordination:
- MRP Purchase Auto-Generation: Auto-convert MRP recommendations into structured requests for quotation and POs.
- Blanket & Scheduled POs: Manage annual bulk contracts with weekly release call-offs to optimize warehouse space.
- Supplier Quality Rating: Track supplier defect rates, delivery delays, and Certificate of Analysis (COA) compliance.
- External Supplier Portal: Suppliers confirm delivery dates, submit advanced shipping notices, and upload lab test sheets.
Plant Maintenance 10. Equipment & Asset Maintenance (CMMS / EAM)
Maximize machine uptime and prevent catastrophic breakdowns through scheduled preventive and predictive maintenance:
- Preventive Maintenance Calendars: Schedule periodic servicing based on running hours, cycle counts, or calendar days.
- Machine Reliability Metrics: Automated calculation of Mean Time Between Failures (MTBF) and Mean Time to Repair (MTTR).
- Breakdown Work Orders: Rapid dispatch of maintenance technicians upon operator breakdown reporting.
- Maintenance Spare Parts Inventory: Track critical bearings, belts, and motors with automated minimum-level reordering.
Labor & Shifts 11. Shop Floor Labor & Shift Tracking
Monitor operator productivity, attendance, machine assignments, and labor cost absorption across production shifts:
- Shift Roster Management: Configure 2-shift or 3-shift 24/7 continuous production rosters with crew rotations.
- Operator Skill Qualification: Ensure only certified operators are permitted to sign into specialized CNC or laser machinery.
- Direct vs. Indirect Labor Hours: Segregate productive machining hours from cleaning, maintenance, and idle time.
- Operator Efficiency & OEE: Measure individual operator output rates against standardized cycle time expectations.
Cost Accounting 12. Manufacturing Cost Accounting & Variance
Accurate manufacturing cost rollups combining material consumption, direct labor, machine overhead, and scrap losses:
- Standard Cost vs. Actual Cost: Compare pre-calculated standard product costs against actual production batch costs.
- Manufacturing Variance Breakdown: Deconstruct variances into Material Usage, Material Price, Labor Rate, and Overhead.
- WIP Balance Capitalization: Accurately capitalize Work-in-Progress asset values at month-end closing.
- Scrap & Rework Costing: Quantify the true financial impact of scrap rates and rework labor on gross product margins.
Safety & EHS 13. Compliance, Safety & Environmental Standards
Maintain plant safety, industrial hygiene, environmental sustainability, and international manufacturing certifications:
- Safety Incident Logging: Track near-misses, workplace injuries, lost time incidents, and root-cause analyses.
- Safety Data Sheets (SDS): Central digital repository for hazardous material handling instructions and chemical safety.
- Periodic EHS Inspection Audits: Standardized checklists for fire extinguisher audits, emergency exits, and machine guards.
- ISO 9001 / ISO 14001 Defensibility: Complete digital audit trail supporting third-party certification renewal audits.
Energy & Utilities 14. Energy, Power & Utility Consumption Monitoring
Monitor electricity, natural gas, steam, and water consumption per production unit to lower manufacturing carbon footprints:
- Sub-Meter Telemetry Integration: Ingest real-time electricity and gas consumption data from shop-floor smart meters.
- Energy Cost per Manufactured Unit: Correlate real-time KWh power consumption with specific production work order batches.
- Peak Tariff Load Management: Alerts when factory power demand approaches maximum contractual peak tariff thresholds.
- Utility Anomaly Detection: Detect compressed air leaks and cooling water waste during scheduled non-operational hours.
Industrial IoT 15. Industrial IoT, PLC & SCADA Machine Telemetry
Direct machine-to-cloud connectivity streaming real-time sensor data from factory PLCs, CNC controllers, and sensors:
- Industrial Protocol Connectors: Support for OPC-UA, MQTT, Modbus TCP, and Siemens S7 machine communications.
- Automated Cycle Counting: Machine sensors automatically record part completion counts, eliminating manual tallying.
- Live Machine Status Indicators: Real-time visualization of machine states (Running, Idle, Fault, Setup) on factory floor monitors.
- Vibration & Temperature Telemetry: Predictive condition monitoring detecting anomalous bearing heat and vibration spikes.
OEE Intelligence 16. Manufacturing Intelligence & OEE Analytics
Transform raw machine telemetry into standardized Overall Equipment Effectiveness (OEE) metrics and executive reports:
- Real-Time OEE Scorecards: Automatically compute OEE = Availability × Performance × Quality across every machine.
- Six Big Losses Categorization: Quantify losses due to equipment failure, setup adjustments, idling, and defects.
- Plant Production Heatmaps: High-visibility dashboards for factory floor display screens showing live shift pacing.
- Comparative Line Benchmarking: Benchmark productivity and scrap rates between sister manufacturing plants and shifts.
Sales Order Sync 17. Sales Orders & Customer Order Fulfillment
Synchronize sales demand directly with production schedules under Make-to-Order and Make-to-Stock operating models:
- MTO & MTS Production Triggers: Automatically trigger work orders directly upon customer sales contract confirmation.
- Available-to-Promise (ATP) Engine: Provide sales reps with realistic delivery dates based on active machine capacity.
- Shipping Staging & Palletizing: Manage packing lists, shipping marks, container loading diagrams, and export documents.
- Finished Goods Quality Sign-Off: Mandatory final inspection sign-off before goods can be released to shipping bays.
Rework & Returns 18. Returns, Rework & RMA Management
Structured handling of customer returns, failure analysis, warranty validations, and authorized shop-floor rework orders:
- RMA Request Authorization: Customer returns validation against serial numbers, warranty dates, and delivery batches.
- Root-Cause Failure Analysis: Laboratory testing determining whether defect was manufacturing, transport, or client-induced.
- Shop-Floor Rework Routings: Specialized rework work orders that consume additional labor and components to restore parts.
- Scrap Material Reclamation: Reclaim valuable metals, plastics, and off-cuts back into raw material inventory buffers.
Technical Vault 19. Technical Documents, Drawings & CAD Vault
Centralized engineering document repository delivering paperless work instructions directly to shop-floor terminals:
- Paperless Shop Floor Instructions: Operators view high-resolution PDF engineering drawings and assembly SOPs at kiosks.
- Video Assembly Tutorials: Embed multimedia standard operating procedures for complex manual assembly workstations.
- Controlled Drawing Distribution: Prevent obsolete paper blueprints on the shop floor with dynamic watermarking.
- Inspection Plan Attachments: Attach dimensional tolerance sheets directly to quality control workstation screens.
Manufacturing Rules 20. Workflow & Manufacturing Process Automation
Eliminate manufacturing administrative bottlenecks with automated trigger-and-action industrial rules:
- Automated Operation Progression: Completion of cutting operation automatically releases subsequent welding work orders.
- Maintenance Auto-Dispatch: Machine sensor reaching 5,000 cycles automatically schedules lubrication work requests.
- Quality Hold Automation: Three consecutive defective inspection measurements automatically halt the production line.
- ERP Ledger Auto-Postings: Work order completion automatically moves inventory from WIP to Finished Goods ledgers.
Machine Gateway 21. API Gateway & Machine Integration Hub
Robust connectivity layer uniting NavMSM with plant hardware, SCADA servers, and enterprise ERP systems:
- SCADA & PLC Bridges: Industrial edge gateways polling factory automation controllers and pushing data to cloud.
- Enterprise ERP Synchronization: Seamless bi-directional financial sync with NavERP, SAP, and general ledgers.
- Barcode & Zebra Printer Integration: Direct printing of serialized weatherproof pallet labels and metal nameplates.
- Third-Party Logistics (3PL) APIs: Push finished goods shipping advice directly to freight forwarder and shipping systems.
Cybersecurity 22. System Administration & Cybersecurity
Industrial cybersecurity safeguarding manufacturing plants against cyber threats, tampering, and unauthorized data leakage:
- Kiosk & Badge Authentication: Operators tap RFID badges to sign into shop floor touchscreens quickly and securely.
- Fine-Grained Industrial Permissions: Protect formulas, cost structures, and machine configurations from unauthorized access.
- Immutable Production Audit Trail: Complete cryptographic log of every work order adjustment, scrap write-off, and parameter change.
- Local Edge Buffering: Factory floor kiosks continue logging production during temporary internet outages, syncing upon restore.
Our Technology Stack & Engineering Standards
We engineer enterprise business software with proven technologies, strict relational data integrity, clean security models, and high operational reliability:
Django Backend & Python
Industrial manufacturing backend built on Django with heavy-duty relational ORM transactions, async Celery queues, and RESTful APIs.
Bootstrap 5 & Kiosk UI
Clean, responsive plant dashboard and high-contrast, touch-friendly shop floor kiosk interfaces for rugged industrial environments.
MySQL / MariaDB Multi-Tenancy
Optimized relational database with multi-tenant isolation, high-frequency telemetry tables, and automated off-site encrypted backups.
OPC-UA / MQTT IoT Protocols
Native industrial IoT protocol support connecting directly to factory floor PLCs, CNC controllers, smart meters, and barcode scanners.
Our Software Development Lifecycle (SDLC)
Every enterprise deployment follows our structured, ISO-aligned Agile lifecycle ensuring zero scope surprises, verified data integrity, and rapid staff adoption:
Shop-Floor Audit & Line Mapping
We audit your factory layout, production workstations, multi-level BOMs, routing sequences, and machine telemetry interfaces.
BOM & Routing Architecture Design
We configure multi-level BOM hierarchies, work center hourly rates, scrap loss factors, and finite capacity scheduling rules.
Agile Sprints & Machine Telemetry Setup
We develop and configure modules in two-week agile sprints, deploying shop-floor touchscreen kiosks and IoT sensor gateways.
Production Simulation & Traceability QA
Rigorous dry-run verification of MRP explosions, capacity scheduling algorithms, batch lot traceability, and OEE calculations.
Raw Material Migration & Operator Training
Secure migration of material masters and opening stock, followed by hands-on training for machine operators and plant managers.
24/7 SLA Support & Continuous Optimization
Continuous industrial support, plant reliability tuning, new machine line integrations, and ongoing software scaling.
Why Choose 92Technology as Your Software Partner
Proven enterprise engineering, multi-domain expertise, and end-to-end accountability delivering bespoke software solutions tailored to your operational realities.
Real-Time Overall Equipment Effectiveness (OEE)
Automatically calculate OEE (Availability × Performance × Quality) directly from machine sensors to eliminate hidden factory downtime.
Multi-Level Dynamic Bill of Materials (BOM)
Manage deep engineering component hierarchies with accurate scrap percentages, yield factors, and automated cost rollups.
End-to-End Batch & Lot Traceability
Complete backward and forward traceability linking finished product serials directly back to raw material supplier batches.
Finite Capacity Scheduling (MPS & MRP)
Prevent machine bottlenecks and missed delivery dates with intelligent finite capacity scheduling and automated material explosion.
Touchscreen Kiosks for Shop-Floor Operators
Replace error-prone paper job traveler sheets with rugged touchscreens that let operators view drawings and log output easily.
Dedicated Local Industrial Engineering Support
Direct on-site and remote assistance from our experienced manufacturing software engineers in Karachi, Lahore, and Islamabad.
Ready to Build Your Manufacturing Execution System?
Speak with our industrial software engineers in Karachi, Lahore, and Islamabad to analyze your factory production workflows, evaluate machine IoT connectivity, and plan your custom implementation.
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