We build the software that runs your plant.
From PLC signals to the ERP, VZIAM designs, builds and integrates the systems production depends on. Most of that work runs on VZIAM MES, the manufacturing execution system we develop and maintain ourselves.
- OPC UA
- MQTT
- HTTP
- Modbus
- Siemens S7
The ERP knows the plan. It does not know what happened at 09:12.
Orders, stock and costs live in the ERP. What the machines actually did (the stop, the slow cycle, the reject) lives on the floor, in shift notes and in people’s heads. Three questions stay open.
Why is this line producing less?
A stop, a slow cycle, a reject. Without the machine, the order and the reason attached to each, the end-of-shift figure says something was lost, not where.
Which batches are affected?
When a material lot is in question, the links from it to every finished batch should already exist, not be rebuilt from paper while the customer waits.
Who has the right information?
Production, quality and maintenance each hold part of the story in their own file. Decisions wait while somebody reconciles them.
VZIAM sits between your machines and your ERP.
The ERP plans the orders, the machines run them, and VZIAM MES records what happened and passes it on: orders and items in from the ERP, quantities, consumption and times back.
Machines and gateways
States, counters and process values
Operators at the station
Terminal · forms · declarations
Reasons, checks, readings and consumption
VZIAM MES
Machine · work order · item · batch
- Production and OEE
- Quality and traceability
- Batch records, forms and maintenance
ERP
Orders and items in; quantities, consumption and times back
Dashboards and Andon
Timelines · OEE · loss Pareto · alerts
- Reads from
- PLCs over OPC UA and MQTT; Modbus and S7 through a gateway
- Covers
- Production and OEE, quality, traceability, batch records, forms, maintenance and station documents
- Exchanges with
- Your ERP, over a REST API or JSON and CSV files
- Runs
- Docker, on a server on your network
VZIAM MES
A manufacturing execution system: it reads the machines, records stops, checks and materials against the work order, and returns the result to the ERP. It includes maintenance, on the same record as production.
For maintenance teamsVZIAM CMMS
A dedicated CMMS for maintenance teams that want a specialised tool of their own: work orders, preventive plans, the equipment register, spare parts and a mobile app for technicians.
One machine stop becomes one decision, in five steps.
The machine reports a stop, the system attaches it to the running order, the operator gives the reason, checks are recorded against the same run, and the order’s record is ready for review, with nothing typed twice.
The machine reports its state and counter over the connection it already has.
Machine data acquisitionIn the record
- Source
- OPC UA · MQTT
- Equipment
- Line 02
- Event
- Stop detected, 09:12
The stop is attached to the running work order, the item and the shift.
In the record
- Work order
- WO-0248
- Item
- Product A
- Shift
- Morning
The operator picks the reason from a shared list, on the terminal beside the line.
Downtime trackingIn the record
- Reason
- Waiting for material
- Duration
- 18 min
- Declared at
- Line 02 terminal
Quality checks and forms are recorded against the same run, so each result keeps its context.
Quality managementIn the record
- Check
- Packaging integrity
- Result
- Recheck required
- Batch
- LOT-248
The order’s record now holds its stops, checks and materials together, ready for the review.
Batch recordsIn the record
- Record
- Operations · checks · materials
- Losses
- Stops ranked by duration
- Output
- PDF summary · Excel export
Seven modules on one record. Start with one.
Every module reads and writes the same record of machines, orders and batches, so a plant can start with one and add the others later.
A stop stops being a blind spot.
Run and stop periods per machine, reasons qualified at the terminal and corrections justified, OEE, OOE and TEEP from the same timeline, reference rates per item and machine, work orders with their routing, and results by shift, including manual stations with no machine to read.
How the OEE engine calculates- Main reason
- Waiting for material
- Context
- Line 02 · WO-0248
The check keeps its context.
Control plans, operator self-checks, scrap and reject reasons, non-conformities and rechecks, each linked to the order, batch and machine that produced it, with the plan version, results, attachments and named sign-offs a release review asks for.
Quality management- Appearance
- Conforming
- Net weight
- Conforming
- Packaging integrity
- Recheck required
Follow a batch back to its materials.
Batch genealogy in both directions, material consumption recorded against the operation that used it, each finished lot linked to its work order, and lot codes generated to your own rules.
Traceability- MaterialsLOT-MP-012LOT-MP-018
- Work orderWO-0248
- Finished lotLOT-PF-248
The order is finished. Is its history in one place?
The operations actually run, the routing as it was applied, materials reconciled against the bill of materials, and the checks and stops of the same order, as a PDF summary to share and a CSV export that opens in Excel.
Batch records- Operations actually run
- Included
- Materials and reconciliation
- Included
- Checks and stops
- Included
The checklist stops being a loose sheet.
A form designer for checklists, cleaning sheets, line start-ups and parameter readings: typed fields with tolerances checked as values are entered, conditional questions, due at the start or end of an order or periodically, with a co-signature where the template asks for one, and read-only once submitted.
The paperless shop floor- Cleaning verified
- Yes
- Temperature reading
- 72 °C
- Sign-off
- Named supervisor
From a report on the line to a closed intervention.
Requests raised from the line with the machine, sub-assembly and severity attached; interventions planned, assigned and closed with a report; preventive plans; spare parts and stock thresholds; and MTBF and MTTR over the period you choose.
Maintenance in VZIAM MES- Equipment
- Outfeed conveyor
- Reported
- Abnormal noise
- Assigned to
- Maintenance team
The instruction at the station is the current one.
Work instructions and one-point lessons attached to machines, items and orders, shown at the station they apply to, with every revision kept, and one search across the whole application.
Work instructions at the station- Document
- Changeover instruction
- Revision
- C, current
- One-point lesson
- Guide rail setting
OEE from machine signals, not typed totals.
OEE is availability × performance × quality. VZIAM MES calculates it on the server, to AFNOR E60-182, from machine signals. The same three factors point to different causes, so the figure is always shown with its losses.
- Availability
- 93%
- Performance
- 89%
- Quality
- 95%
Stops, longest first34 min
- Waiting for material
- 18 min
- Changeover
- 11 min
- Breakdown
- 5 min
Availability carries the loss. The question it raises: Why is Line 02 waiting when the order is ready?
Your line, in perspective
What do 20 minutes a day add up to?
Minutes × rate × days, nothing else. It ignores scrap, demand and every other constraint.
Book a callFour kinds of floor, one record.
Discrete and process manufacturing. Each industry page shows the record VZIAM MES keeps on that kind of floor, and who reads it.
- RecallSupplier recall · Steel coilBracket stamping
Automotive
Each finished lot traced to its material and its machine.
Read the page - HeldBatch record · Cooking lineTomato sauce
Food Processing
The batch record, written while the batch runs.
Read the page - RunningPress 07 · InjectionHousing cover
Plastics
Cycle time read from the press, not from the shift report.
Read the page - 1 own · 2 inducedBottling line · Stops75 cl format
Packaging
Finding the one machine that actually stopped the line.
Read the page
What we build, and how a project runs.
Four layers, built to fit what you already run. Four steps, with no surprises in between.
Machine data acquisition
Connections to PLCs over OPC UA and MQTT, with a gateway for Modbus and S7. No manual entry in the path.
Execution & MES
Operator terminals and execution logic for what a machine cannot report: downtime reasons, quality declarations, checks, forms and consumption.
ERP integration
Work orders, articles and bills of materials pulled from SAP, Sage or Microsoft Dynamics; good quantities, rejects and cycle times posted back when each order closes.
Analytics & reporting
OEE to AFNOR NF E60-182, loss Pareto and shift reports, calculated from PLC signals and published where your teams already look.
- Step 01
Assess
We walk the floor, map the machines and the data that already exists, and agree what “done” means before anything is built.
- Step 02
Pilot
One line, one machine, real signals, in weeks. You check your own data before you commit to a rollout.
- Step 03
Build
Delivered in increments against the agreed scope, on your network, with your team in the loop.
- Step 04
Run
Support, monitoring and changes after go-live. What we built stays ours to answer for.
VZIAM MES is a manufacturing execution system: software that records what actually happens on the shop floor (machine states, stops, quantities, checks and materials) against the work order it belongs to, and sends the result back to the ERP.
The ERP plans: orders, stock and costs. The MES executes and records: which machine ran which order, when it stopped and why, what was consumed and what passed inspection. VZIAM MES exchanges orders and results with the ERP rather than replacing any of it.
Production and OEE, quality, traceability, batch records, forms, maintenance and station documents, all on one record of machines, orders and batches. A plant can start with one module and add the others later.
OEE is availability × performance × quality. Availability is the share of planned time the machine ran, performance is its speed against the reference rate, and quality is the share of output that was good. At 93% availability, 89% performance and 95% quality, OEE is 78.6%.
Both. Most projects start from VZIAM MES and are extended to fit the plant. Where a plant already runs something that works, we integrate with it rather than replace it.
On-prem. VZIAM MES runs as Docker containers on a server on your network (the database, the application and an MQTT broker for the machine signals), so capture does not depend on a connection to anywhere else.
Machine states and counts are read from the PLC rather than typed in, and OEE is calculated on the server to AFNOR E60-182. A correction is still possible, but it is recorded with who made it and why.
OPC UA, MQTT and HTTP push natively. A Modbus, Siemens S7 or proprietary PLC connects through a gateway on the line (Node-RED or a DAS box) that translates its signals to MQTT, and the assessment says which of your machines need one.
Yes. A manual station is an operation in the routing like any other: its start, end, quantities and checks are declared on the terminal, so the work order’s record covers it as well as the connected machines.
With an assessment of the floor, then a pilot on one line with real signals before any rollout commitment.
Yes, in two forms. VZIAM MES includes maintenance: requests raised from the line, interventions, preventive plans, spare parts, and MTBF and MTTR. VZIAM CMMS is a dedicated application for maintenance teams that want a specialised CMMS of their own.
Plan the change before it reaches the line.
Request a demo and an engineer looks at how your production runs today, shows how the software would fit around it, and where a pilot on one line would start.
01Pick a time
Choose a slot in the calendar, and note what you make and what reads your machines today.
02Screen shared with an engineer
A video call with someone who builds the software, in English or French.
03What would connect
For each machine, its path: native (OPC UA, MQTT or HTTP push), through a gateway, or nothing to build.