AI-Integrated MES
for small and mid-sized manufacturers

A finished product that manages order intake, production planning, shop-floor results, materials, quality, equipment, TOOL and shipping on one set of master data. Implemented to fit each customer's processes.

Request free assessment +82-10-3656-7711 19 simulation videos

AI-Integrated MES screen recording · sample data

Enterprise management system

Shop-floor signalsRead-only collection

Equipment PLCModbus · OPC UA
Vision inspection equipmentOK · NG result intake
SensorsMQTT · IO‑Link
Shop-floor tablet · QRResults · andon call
CCTV cameraRTSP · ONVIF

Manufacturing executionProduction, quality, equipment

AI-Integrated MESMaster data source · KPI ledger · alarm ledgerProduction · planningQuality · traceabilityEquipment · TOOLMaterials · shippingFactory 3D digital twin
AI vision nonconformance responseIn operation on siteResult → action · lot history
AI CCTV safety monitoringIn developmentIn-plant video analysis

Management analysisCost, accounting, approval

CostCOSMO
Accounting · taxFACTS
Approval · documentsE-approval · KEYSTONE

People · organizationRoster unified at implementation

HR · payrollHRMS · AI_HRD
Shop-floor performance evaluation35 items in 7 areas
Shop-floor communicationSotong48 · QR intake

ExpansionNew systems added

AXB planning automationRequirements → planning documents
New systemConnected on the same master data

Enterprise management systemIntegrated configuration at customer implementation

Single master data
Single roster · permissions
Single cost · accounting ledger

Select a node to show its connections

Expansion structure

Element	Description
Master data	Items, BOM, processes, equipment, TOOL and work groups managed in one place in the MES; connected systems use the same codes
Shop-floor connection	Equipment, cameras and inspection equipment connected through standalone collector programs (PLC and camera connections in development); devices added through device registration and authentication key issuance
Alarm ledger	Production alarms and safety alarms managed in one ledger from occurrence → acknowledgment → resolution
System connection	Cost, accounting, HR, approval and document systems can run standalone; at implementation, connection modules share MES master data and results
Digital twin	Equipment status, andon and safety events on a 3D factory layout, TV status board · configured with the customer's layout and equipment signals at implementation
Expansion sequence	Start with one of AI-Integrated MES · equipment anomaly monitoring · a standalone system, then combine in stages on the same equipment codes and master data

AI-Integrated MES

Data pipeline

Order intake · delivery planningCustomer · item · due date
Production planningFinished goods → sub-level plans
Requirements explosionMulti-level BOM explosion
Purchasing · incoming inspectionReceiving lots created, only accepted lots issued
Work ordersExpanded by process sequence
Shop-floor resultsMaterials · TOOL strokes updated automatically
Lot genealogyRaw material → WIP → finished goods
Outgoing inspectionOnly accepted lots can be shipped
Shipping · deliveryRecorded in a single transaction

Delivered quantity → order intake · delivery plan updated automatically

Outsourced process: issue → receiving inspection → return to process. One shop-floor result updates material deduction · TOOL strokes · lot genealogy · work order status at once.

Scope of management

Area	Functions
Master data	Items, BOM, processes, routings, equipment, TOOL, work groups, business partners, standard time (C/T)
Sales · planning	Order intake, weekly delivery plans, finished-goods plan → batch expansion into work orders by process, advance production by lead-time backward scheduling, capacity and load, projected available inventory
Purchasing · materials	Raw material coil receiving, incoming inspection and consumption, purchase order suggestions and receiving, outsourcing issue, receipt and loss, finished goods and WIP inventory, monthly payables closing
Production · equipment	Work group tablet results, downtime, availability, OEE, staged andon calls, error code diagnostic dictionary, TOOL strokes, service life and inspection
Quality · development	Incoming, in-process and outgoing inspection, SPC, Gage R&R and gauges, nonconformance and 8D, containment and recall, forward and backward lot traceability, internal audits and LPA, change points, APQP and PPAP
ESG · safety	Energy metering and carbon conversion, safety alarm ledger (when cameras and sensors are connected)
Management analysis · AI	Dashboards (OEE, production trends, defect causes), sales analysis and on-time delivery rate, cost roll-up · defect risk prediction, SPC anomaly detection, predictive maintenance signals (processed in-plant) · root cause analysis drafts, natural-language queries (external AI, optional)
Digital twin	3D factory layout, equipment status, andon and safety event display, TV status board (configured with the customer's layout and equipment signals at implementation)
Scale	88 management menus (as of October 2026), separate shop-floor tablet screens, web browser access

Management KPIs

Category	KPI	Calculation basis
Production	Output · defect rate · work order achievement rate	Aggregated as soon as shop-floor results are entered
Production	Actual UPH · achievement rate against standard UPH	Based on effective working time; quantity-weighted standard UPH for multi-product equipment
Equipment	Availability	Operating time ÷ loading time (working hours − meals and planned stops), reflecting the operating calendar and holiday work
	OEE (time availability × performance efficiency × yield)	Based on work sessions, standard UPH and good parts; equipment that cannot be measured shown separately
	Downtime reason Pareto	Planned and unplanned classification, time and count by reason code
	Mean andon response · mean repair time Video	Call → acceptance → arrival → resolution times recorded
Quality	Process PPM · nonconformance type Pareto · open nonconformances	Nonconformances registered automatically on result defects or inspection failures
	Cp · Cpk · Pp · Ppk · out-of-control (8 Nelson rules) Video	Calculated as soon as a subgroup is registered; Cpk criteria by production phase
	%GRR · ndc · gauge calibration status	ANOVA and average-and-range methods, calibration intervals calculated automatically
	Quarantined lots · affected shipped lots Video	Raw material, WIP, finished goods and shipped lots expanded automatically when a containment case is opened
	Supplier incoming PPM · rating grade	Incoming PPM aggregated automatically from incoming inspection results; grade is a weighted sum of quality (incoming PPM), delivery, responsiveness and cooperation scores
TOOL	Usage against guaranteed strokes · estimated remaining days	Strokes accumulated automatically from shop-floor results (good + defective)
TOOL	TOOL MTBF (stroke-based) · MTTR · inspections due	Based on maintenance and inspection history
Materials	Raw material consumption per unit · available balance · producible quantity	On result registration, coils that passed incoming inspection are deducted automatically in order of receipt
Materials	Projected available inventory · days of inventory · order suggestions	Available inventory = previous inventory + production − demand; order suggestion = BOM-exploded requirement − on-hand inventory − open purchase orders
Delivery	On-time delivery rate · weekly delivery plan achievement rate · delays	Aggregated automatically from delivery slips
Safety	Unacknowledged alarms · mean acknowledgment and closure time · false alarm rate	When cameras and sensors are connected
ESG	Energy consumption · carbon emissions	Meter reading input → emission factor conversion

Structure

Processing	Result
One result entry → TOOL strokes, raw material and purchased part deduction, lot genealogy and work order status updated at once	No separate ledger re-entering the same numbers
Availability, UPH and OEE calculated in one time-calculation module (shifts, meals, non-working time, holiday work)	No conflicting availability figures across screens
Materials that failed incoming inspection blocked from use, failed lots held automatically, only lots that passed outgoing inspection shipped	Defect outflow paths blocked by the system
Customer claim received → containment case opened → affected lots quarantined automatically	Quarantine scope expanded automatically to lots sharing the same raw material or process (based on input records)
Cause and action entry required to close nonconformances and SPC violations	No closure without a recorded cause
Sessions under 10 minutes or over 3× standard excluded from UPH aggregation only, with the excluded count disclosed (output quantity and downtime still aggregated)	KPIs protected from distortion by input errors
Change history recorded automatically (user, modified fields, deleted rows)	Traceable record changes

Workflow

Operator entering work results on a tablet in front of a press line — Press line · tablet result entry (sample image)

Role	Screen	Tasks
Shop-floor operator	Work group tablet	Select work order → select operator and equipment → start → enter good and defective quantities → finish. Downtime registration, andon call
Group leader · supervisor	Work group status · andon	Progress and downtime review; andon acceptance, arrival and resolution
Quality staff	Inspection · nonconformance · SPC	Judgment and hold release, nonconformance disposition, control chart violation actions
Production control	Production planning · work orders	Plan registration → batch expansion into work orders by process; capacity, load and days of inventory review
Management	Dashboard · sales analysis	OEE, production trends, defect causes, on-time delivery rate, delivered amount

Simulation

Actual system screens recorded with fictitious sample plant data. Company names, part numbers and personal names are fictitious. Videos show the Korean-language system screens and captions.

Order intake → production planning → work ordersAI-Integrated MES · 0:38

AI-Integrated MES5 videos

Features in development2 videos

Standalone systems12 videos

Remote demo of actual screens by system · fictitious sample data · approx. 40 minutes

Request remote demo

Configuration

Component	Scope	Data to register first	Expansion
AI-Integrated MES	From sales to shipping and closing	Items, BOM, processes, equipment, work groups	Equipment signal and camera connection
Equipment anomaly monitoring In development	Equipment signal collection (PLC connection in development); stop, andon and error code diagnostic dictionary (standard MES functions)	Equipment list	Item and BOM registration → entire MES
AI CCTV safety monitoring In development	Detection of dwelling in hazard zones, forklift–person proximity and missing hard hats	Camera placement and monitored zones	Connection to the MES alarm ledger
Standalone systems	HR and payroll, cost, accounting, approval and documents, etc. (list below)	System-specific master data	MES connection modules developed at implementation

Operator checking equipment operating status on a shop-floor tablet in front of an equipment control panel — Equipment control panel · shop-floor tablet (sample image)

Equipment anomaly monitoringIn developmentAI-Integrated MES extension · PLC signal connection

CollectionPLC read-only · Modbus TCP, OPC UA (signing and encryption)

SignalsRun · stop · production count · current · temperature

Safety signalsEmergency stop · safety door · light curtain contact alarms

Diagnostic dictionary25 equipment model families · 692 error codes (cause, inspection sequence, LOTO cautions, countermeasures)

AndonGroup leader 0 min → supervisor 5 min → maintenance and quality 15 min → plant manager 30 min

Equipment controlNone (no write functions)

StatusAndon and diagnostic dictionary: standard AI-Integrated MES functions · PLC signal collection: in development

Wiring and signal mapping per model confirmed for each piece of equipment during the site survey.

Main equipment models in the diagnostic dictionary

PLC: Mitsubishi MELSEC-Q·FX, Siemens SIMATIC S7, LS ELECTRIC XGK·XGT, Omron CJ·CS·CP·NX·NJ, Allen-Bradley Logix, Panasonic FP
Servo and inverter: Mitsubishi MELSERVO/FR, LS ELECTRIC iS7/iG5A/S100, Panasonic MINAS, Yaskawa V1000/A1000/GA700, Allen-Bradley PowerFlex
Robots: FANUC, KUKA KRC4, Hyundai Robotics Hi5/Hi6, Yaskawa Motoman
Others: Keyence vision and sensors, mechanical presses, hydraulics and pneumatics, safety devices

View simulation · 0:30

Factory floor with separated safety walkways and equipment zones — Factory safety walkway · equipment zone (sample image)

AI CCTV safety monitoringIn developmentCustom implementation

DetectionDwelling in hazard zones · forklift–person proximity · missing hard hats

RecordsAlarm history that cannot be edited or deleted, face-masked snapshots, shift handover

ReportsMean acknowledgment time · mean closure time · false alarm rate

CamerasRTSP IP cameras (H.264, FHD recommended) · in-camera AI events (ONVIF Profile M)

Video processingIn-plant server; no video leaves the site

OptionPress guard defeat monitoring (video × PLC signal cross-check)

Detection models calibrated with on-site video and put into operation after accuracy verification. Auxiliary alarm device; equipment stops are handled by safety PLCs and light curtains.

View simulation · 0:26

Connection specifications

Inspection line where a vision camera inspects pressed parts — Vision inspection line (sample image)

Target	Method	Conditions
PLC In development	Modbus TCP · OPC UA	Read-only
In-camera AI · sensors	MQTT (ONVIF Profile M, IO‑Link, etc.)	Event reception; manufacturer-specific formats verified on actual devices
IP camera video In development	RTSP (H.264)	Processed on in-plant server
Vision inspection equipment	HTTP events (OK/NG)	Authentication key per equipment unit
Shop-floor collection PC	Standalone gateway → HTTP transmission to MES	Authentication key per device

Standalone systems

System	Functions
Integrated HRMS In operation on site	Daily attendance by work group and shift, annual leave, payroll settlement (Labor Standards Act formulas) — for shop-floor production staff Video
AI_HRD	Attendance summary, annual leave, payroll, four major social insurances, year-end tax settlement, 52-hour workweek check — company-wide payroll including office and management staff Video
Shop-floor performance evaluation In operation on site	100 points over 35 items in 7 areas (system-calculated 28 points · evaluator-scored 72 points) Video
AI vision nonconformance response In operation on site	Vision inspection result intake → equipment action instructions · inspection, alert and action history by lot Video
COSMO cost management	Structured Excel cost statements; comparison by part number of contract vs. actual cost and at-quotation vs. current basis Video
FACTS accounting and tax	Automatic journal entries, closing, financial statements and VAT return data, approval history retention Video
E-approval	Approval of original Excel, Hangul (HWP) and PDF files, sealing of approved documents and change detection Video
KEYSTONE document management	Document registration, revision and viewing by department and task, proxy succession during absence Video
Sotong48 In operation on site	QR intake of grievances, reports and suggestions, 48-hour response deadline management, anonymous, Korean, Nepali and Khmer
Meal pre-registration	Advance headcount for lunch and dinner (based on Google Sheets) Video
BizMap business card management	Business card search by place, impression and introducer clues Video
AXB planning automation	Requirements Q&A → planning document set Video
SME AX consulting	350 manufacturer pain points selected → improvement plan draft · AX pain-point checklist (Korean) Video

In operation on site: systems running at manufacturing sites. Built new for customers on the same design.

Terms

Process

Site survey1 day · free
Process, equipment and paperwork flows; Excel files and systems in use
Scope definition1 week
Starting scope and connection scope defined, quotation
Pilot4 weeks
Live operation with customer data, effect verification
ExpansionBy agreement
Next scope added to existing master data. Equipment code mapping when a standalone system was introduced first

Duration varies with process scale and equipment condition. Cost quoted after scope definition.

Server · data

InstallationServer inside the customer's plant available

AccessWeb browser (no software installation)

Data ownershipCustomer; exportable

On contract terminationFull return, then deletion of our copies

Source codeThird-party escrow (agent and cost agreed at contract)

DB schema · operation documentsIncluded in deliverables

Incident response

Contact channelsPhone and email, weekdays 09–18 KST

First responseWithin 4 business hours

Remote actionSame day as report (when remote access is permitted)

On-site visitNext business day (agreed service area)

Nights · holidaysHandled next business day (urgent cases handled remotely once confirmed)

Equipment impactNone (equipment runs regardless of system downtime)

Warranty · maintenance

Contracting partyAXB Co., Ltd. (contracted after incorporation)

Free warranty repair12 months after acceptance

Warranty scopeDeviations from delivered specifications, defects

MaintenanceAnnual contract after the warranty period

Regulatory updatesScope and frequency specified in the contract

New featuresQuoted separately (defect vs. new feature per the contract list)

Third-party maintenanceNo restrictions after escrow release

Exclusions

24/7/365 resident support
Guarantee of accident prevention by safety monitoring — not a substitute for legally required safeguards
Monetary guarantee of implementation effects
Guarantee of passing certifications or audits

Government support programs

Smart Factory Construction Support ProgramNot a registered supplier (as of October 2026); implementation through this program not available

Smart factory level verificationCompanies that implemented on their own and obtained level verification may apply for advancement programs (per the 2026 government-type announcement; selection determined by evaluation)

AI features and external data transfer

System	AI feature	Processing location	When disabled
AI-Integrated MES	Defect risk prediction · SPC anomaly detection · predictive maintenance signals · demand forecasting	In-plant server	Not applicable
AI-Integrated MES	Natural-language queries · root cause analysis drafts · quality investigation report drafts · plant briefings · appearance photo judgment	External AI (Anthropic Claude)	Only the affected feature stops
AI CCTV safety monitoring	Video analysis	In-plant server	Not applicable
AXB planning automation	Planning document creation	External AI	Template-based creation
SME AX consulting	Plan refinement (optional)	External AI	Rule-based draft
BizMap	Meeting note analysis (optional)	User-specified external AI (own key)	Built-in dictionary analysis
AI_HRD	None (rule-based calculation)	In-plant server	Not applicable

Data transferred externally: query text, DB schema (table and field names), aggregated data for investigations and briefings, photos for appearance judgment. No external transfer when no AI key is configured.

IATF 16949 · records by regulation

System	IATF 16949 · automotive quality system	Regulation
AI-Integrated MES	Control plan (8.5.1.1), SPC (9.1.1.1), APQP and PPAP records, equipment maintenance history, delivered quality ppm, first, middle and last piece inspection	—
AI vision nonconformance response	Control of nonconforming outputs (8.7), problem-solving action history (10.2.3)	—
AI CCTV safety monitoring	—	Monitoring support for Article 38 of the Occupational Safety and Health Act and Article 103 of the Rules on Occupational Safety and Health Standards (press guarding)
Integrated HRMS · AI_HRD	—	Formulas under Articles 55, 56 and 60 of the Labor Standards Act
Sotong48	—	Records of worker opinion hearings under Article 4 of the Enforcement Decree of the Serious Accidents Punishment Act

Summary based on our interpretation. Not a guarantee of passing certifications or audits.

Data storage location exceptions

Sotong48 and meal pre-registration: based on Google Sheets. KEYSTONE document management: based on a cloud server. Configured separately for in-house server operation.

AI-Integrated MESfor small and mid-sized manufacturers