Manufacturing Execution Systems

MES Architecture

From Shop Floor to Enterprise

Our MES solutions bridge the gap between your production floor and your business systems — giving you real-time control, traceability, and insight across the entire operation.

System Architecture

MES sits between your shop floor equipment and enterprise systems — collecting data, controlling parameters, and feeding business intelligence upward.

Shop Floor Integration

Tight integration with your production equipment — PLCs, CNCs, sensors, and control systems — regardless of vendor or protocol.

PLC connectivity (Allen Bradley, Siemens, others)
OPC-UA / OPC-DA standards
Machine parameter setup & automated correction
Real-time data collection per machine, per order
Downtime monitoring & breakdown capture

SCADA & Real-Time Monitoring

Supervisory control and data acquisition — giving operators, supervisors, and managers live visibility into every aspect of production.

Real-time process visualization
Multi-line & multi-site monitoring
Operator HMI design & development
Supervisor workstation dashboards
Alerts & event notification

IoT & Sensor Integration

Connect edge devices, sensors, and smart instruments to your MES — extending visibility to every corner of your operation.

IoT device connectivity & protocol handling
Edge data collection & aggregation
Environmental & process sensor integration
Cloud & on-premise deployment options
Data historian integration

Enterprise Integration

Seamless data flow between your shop floor and business systems — production planning, ERP, and management reporting.

ERP & planning system integration
Production order management
Material & inventory tracking
Quality data capture & traceability
Flat-file, API & database integration options

Reporting & Analytics

Production intelligence that helps you make better decisions — from shift-level summaries to long-term trend analysis.

Shift summary & production reports
Downtime & breakdown analysis
Productivity & efficiency KPIs
Historical analysis & trend reporting
Configurable dashboards & exports

Productivity Tools & Algorithms

Built-in intelligence to improve output and reduce waste — automatic parameter optimization, best-practice capture, and scrap reduction algorithms.

Automated parameter calculation & correction
Best parameter capture per product & tooling
Throughput & yield optimization
Scrap & waste reduction tools
Historical best-run analysis

iPro Works Product

i-EX — Built for Extrusion

A production-proven MES platform developed by iPro Works, specialized for aluminum and metal extrusion operations.

iPro Works Product

i-EX — Intelligent Extrusion Software

i-EX is a proven MES platform developed by iPro Works LLC, purpose-built for aluminum and metal extrusion operations. At its core, i-EX learns from every production run — capturing billet-by-billet data and automatically identifying the best-performing parameters for every unique combination of die, alloy, profile length, and press. The next time that combination runs, i-EX sets the parameters automatically.

From temperature and ram speed to pressure, billet length, and puller settings — every parameter is calculated, set, and continuously refined by i-EX's custom algorithms. Nothing is left to operator memory or manual lookup.

Smart Parameter Setting

Custom algorithms automatically calculate and set billet temp, speed, pressure, length, and run-out for every order — based on previous best throughput for that die/alloy combination.

Billet-by-Billet Recording

Every single billet extruded is monitored and recorded. Operators and managers can go back and review any billet, any order, from any point in history.

Best-Run Intelligence

i-EX automatically identifies the best-performing run for each die, alloy, and length combination and saves those parameters — continuously improving production quality and output over time.

PLC & Die Master Integration

Tight integration with press PLCs via OPC standards — log, shear, quench, and auxiliary systems. Full Die Master management including furnace, soak hours, and die readiness.

Real-Time Monitoring

Live press status, order progress, and productivity metrics across all presses — viewable from supervisor workstations anywhere in the plant.

Extensive Reporting

25+ report types — shift summary, breakdown analysis, die performance, kg/m tracking, historical pivot analysis, and planned order reporting.

i-EX is built on Microsoft technologies with a SQL Server database and OPC standards — designed for reliability and scalability in demanding production environments. Deployed in live extrusion operations and adaptable for other discrete metal manufacturing lines.

Industries

Manufacturing Specialization

Our MES expertise spans metal manufacturing and discrete production environments.

Aluminum Extrusion

Deep specialization — press operations, billet handling, die management, and extrusion process control.

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Metal Manufacturing

Broader metal industry expertise including forming, casting, and other continuous process lines.

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Discrete Manufacturing

Assembly lines, batch manufacturing, and multi-stage production processes across industries.

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Custom MES

Purpose-built MES solutions tailored to your process, equipment, and integration requirements.