MES Solutions Successful Cases
Efficient MES solutions address manufacturing bottlenecks by providing real-time visibility, improving process insights, accelerating issue resolution, and supporting better decision-making.
Success Case
Transform Your Factory with Smarter Production
Applications
Semiconductor
HY ELECTRONIC
HY ELECTRONIC specializes in the R&D, manufacturing, and sales of diodes and bridge rectifiers. Entering mainland China in 1989, the company established Yangzhou Hongyang Electronics Co., Ltd. in 1992, now known as Yangzhou Hongyang Technology Development Co., Ltd. Its complete, advanced, and automated production lines are moving towards full automation. Annual production of diodes and bridge rectifiers exceeds 2 billion units, growing at over 20% annually.
The company’s product R&D focuses on CELL and GPP types. Packaging is evolving from single SIP/DIP to smaller SMD packages. HY ELECTRONIC’s products are widely used in computers, communications, automotive, and consumer electronics. The company is also actively developing new green energy products for applications in LED lighting, solar power, and automotive energy efficiency.
Unified Process Card Format
- Previously, run cards varied across plants, leading to format complexity, multiple templates for the same products, human error, and manual entry.
Consolidation of R&D and Production Information
- Delayed communication of inspection specs between R&D and production prevents real-time access for production lines, causing discrepancies and potential errors between production and R&D.
Unified Process Card Format
- Unified Process Cards: Improving Efficiency and Accuracy with Barcodes
Consolidation of R&D and Production Information
- PLM defines and automatically pushes inspection specifications to SPC, automating the provision of inspection criteria. R&D can set inspection specs in PLM and push count and measurement data to MES. Inspection anomalies in MES are directly fed back to PLM for R&D follow-up.
China Precision Testing Co., Ltd.
We have extensive experience in PCB Layout design, such as transmission lines, differential lines, delay lines, RF, Mix, etc., as well as highly difficult PCB process technologies, such as thick boards, micro lines, high aspect ratios, etc. We also provide Total Solution services such as component assembly (including relays, sockets and stiffeners) and after-sales maintenance.
Main products/services
Probe PCB for wafer testing, probe head, interposer substrate for vertical probe card, load board for IC testing and DUT board for memory testing.
Challenges of incoming materials and inserting
- Urgent orders require time-consuming rescheduling of production management.
- Wrong materials and shortages complicate procurement operations.
- Production management/purchasing staff have complicated tasks and work overtime.
Challenges for factory scheduling and reporting
- Manual scheduling is inaccurate and time-consuming
- Production parameters are not linked to standard parameters
- Unlimited capacity scheduling, no immediate feedback on delivery date
- Decoupling of production information and scheduling
Challenges for factory scheduling and reporting
- Single piece history cannot be mastered
- Shipping report generation takes time
Solution of incoming materials and inserting
- Basic standardization (working hours, processes, materials) Systematically implement standardized material planning
Solution for factory scheduling and reporting
- According to the production capacity and materials, the system implements the production scheduling planning.
- The equipment automatically downloads the production parameters
to schedule according to the limited production capacity and define the effective delivery date . - The feedback scheduling system is updated according to the current status of the production line in real time.
Solution for factory scheduling and reporting
- Management dimension is refined to the version number level. Through RFID, the version number status is automatically transferred to the format definition and the version number traceability record is generated.
Through APS intelligent scheduling management system
• Reasonable schedule for short-time output
– AS-IS: The day and night shift production managers schedule once each, each for about 2 hours .
– TO-BE: Update the schedule based on on-site changes. Generally, the scheduling time is about 5 minutes .
• Transparent delivery scheduling
– Plan the estimated start and completion dates of each process using limited capacity and provide feedback to ERP and MES so that planning and execution can be cross-checked.
• Improve scheduling agility
– Update schedules immediately when changes occur, so production management can clearly understand the dynamics of urgent orders and the production progress within the factory , and re-issue schedules when necessary.
Through MES intelligent workshop execution system
• RFID automatic posting – Batch posting
according to production batch : used before lamination and after molding to effectively control single batch production records. – Posting of individual pieces according to plate number : Applied after lamination and before molding, effectively controlling the production history of each piece.
• Process parameter management
– Completely establish basic specifications, cutting, pre-production stacking, material stacking, drilling, impedance, path and station parameters and other complete product information. - Provides automatic parameter downloading , obtains the processing parameters of each machine through RFID, and avoids setting errors by personnel.
• Production control
– Provides full process management of multiple press plates, and provides complete solutions for pre-press material replenishment, station adjustment, and unit conversion.
– Strengthen cycle time management and provide Move In, Check In, Check Out, and Move Out control for each workstation.
• Quality Control
– Immediately measure quality after production.
- Flexibly set up various shipment inspection reports and their projects, and instantly determine the inspection status and shipment report output.
Applications
Plastic Injection
Chahua Modern Housewares Co., Ltd.
Founded in 1997, Chahua Modern Housewares Co., Ltd. specializes in designing, developing, manufacturing, and selling household goods. As the first “China Well-known Trademark” in the plastic housewares sector, Chahua is a leading company in the Chinese plastic household products industry. In 2017, the company went public on the Shanghai Stock Exchange.
Chahua focuses on R&D, production, and sales of daily-use plastic household items for storage, cleaning, food-related uses, and general home applications. Its product portfolio includes over 1,500 SKUs across five main categories: storage and organization, cleaning, food containers, general household goods, and non-plastic items.
Work Order Size Range
Directly releasing work orders from planned orders：
- Work orders cannot be closed/reconciled daily
- All material requirements are issued to the shop floor and accumulate
- Finished goods work orders can only be assembled at the very end
How to Improve Production Uptime
- Frequent changeovers reduce production uptime, impacting profitability
The system schedules production.
Check the two-week schedule by work order operation.
PlasticsKey Metrics
In the equipment-intensive plastics industry, continuous, efficient, and high-quality production is crucial. Machine utilization can be measured using these three key indicators, complemented by on-time delivery and inventory turnover for a holistic production assessment.
More efficient .That’s what planning and scheduling software does
Metal Processing
Boalian Enterprise Co., Ltd.
Established in 1986, POE LANG ENTERPRISE is dedicated to innovative archery equipment design, aiming for global leadership. Guided by the principle “archery: one arrow at a time,” the company emphasizes meticulous execution. Starting as an OEM, POE LANG ENTERPRISE launched its own brand, “EK Archery,” and expanded into Europe. Through creative marketing and leveraging its extensive experience and intellectual property, EK Archery became the top archery brand in Europe within three years. POE LANG ENTERPRISE prioritizes customer needs and fosters long-term client relationships.
Procurement Follow-Up Procedures
- LRP assumes infinite capacity, yet actual order demand and production start times deviate from LRP projections. Checking “real” future material availability via the WF system is very difficult and time-consuming. High order volumes and frequent delivery date changes make outsourcing and procurement follow-up extremely difficult.
Production Scheduling
- Although past experience allows for initial production planning and line sequencing, volatile customer demand necessitates continuous on-site schedule adjustments by supervisors, resulting in high effort and low real-time visibility.
The risk of missing work orders is present, and discovery of these omissions typically occurs too late for effective corrective action.
Procurement Follow-Up Procedures
- Alerts for pending materials and quantities should be linked to customer orders and their delivery urgency.
- These alerts should connect to relevant purchase orders for supplier follow-up.
- Material usage should be prioritized by order due date, removing manual order checks.
- Inventory status should be readily apparent, removing the need for extra interpretation.
- Part-order associations and part usage should be clearly displayed, removing the need for additional searches.
Production Scheduling
- Synchronized shipping and shop floor schedules improve sequencing accuracy and shipping efficiency.
- APS’s quick search identifies material allocation problems.
- Assembly scheduling prevents missed work orders, improving information flow and reducing risk.
- Real-time work order inventory tracking is available for finished goods, limbs, and fletching.
- Scheduling recommendations adapt to dynamic customer demand.
- Fast report filtering speeds up anomaly detection (missing work orders, allocation issues, etc.).
- Better production sequencing enables more accurate material preparation and minimizes on-site waste (space, changeovers).
- Visualized data
- Greater accuracy
- Simplified processes
- Smoother workflows
- Intuitive operation
- Improved proficiency
Applications
Mechanical Components
REXON INDUSTRIAL CORP.
Founded in 1973, REXON INDUSTRIAL CORP. is a publicly listed company operating in the mechanical, electrical, and electronics industries. With approximately 1,500 employees and operations in mainland China, REXON focuses on two main product categories: fitness equipment and machine tools. REXON is Taiwan’s largest DIY machine tool manufacturer, exporting primarily to the US and Europe.
Products:
- Fitness Equipment: OEM production of elliptical trainers, exercise bikes, treadmills, recumbent bikes, and more.
- Machine Tools: Primarily OEM/ODM of electric woodworking machines and power tools, with a growing focus on its own brand.
- Manual calculation and communication of material needs across plants is labor-intensive.
- Tracking conforming items within outsourced inventory (including defects) is challenging.
- Lack of visualized production data hinders informed scheduling decisions.
- Unsynchronized schedule changes and related documents complicate progress tracking.
- Lack of production and maintenance traceability hinders progress monitoring.
- Per-container material issuance creates inventory discrepancies.
- Inconsistent inbound/outbound flow causes inventory discrepancies.
DURQ MACHINERY CORP.
Founded in 1989, DURQ MACHINERY CORP. is a leading Taiwanese manufacturer of DIY power tools, specializing in high-quality benchtop circular saws and metal cutting machines. With a global market presence, DURQ is recognized for its reliable products and excellent service, partnering with many prominent OEM brands. The company offers a wide range of products, including benchtop and portable cutting machines, band saws, jointers, woodworking machinery, various motors, and CNC machining.
- Manual WIP reporting leads to delayed information and difficult data analysis.
- Disparate production forms prevent data integration.
- Paper-based and Excel-managed production records hinder searchability, traceability, and audit preparation.
- Process quality issues are difficult to detect in real time.
- Production data correlation requires manual effort.
- Limited shop floor visibility hinders real-time situational awareness.
Solutions
- Daily production data - View and analyze daily production by line
- Line and period production report - View and analyze production by line and period
- Serial number repair log - Analysis of repairs by reason and workstation
Starting in February 2020, DURQ MACHINERY CORP. implemented a consulting project. With the collaboration of Sheng Jie Machinery’s management and MES team, the Nangang pilot line was launched in October 2020. By June 2021, all Nangang production lines were online, achieving cost reduction and efficiency gains. Key results include annual labor cost savings of approximately NT$1.
