Industrial Software & Digital Systems
From Shop Floor Data to Intelligent Business Systems
WMS and AGV fleet control. MES integration for OEE and ERP sync. Custom-built industrial applications designed around your production environment — not the other way around.
What We Do
Most factories have automation on the floor and a business system in the office — but a data gap in between. Operators count production manually, supervisors retype numbers into spreadsheets, and management makes decisions on yesterday's data. FERSMEK closes that gap across three interconnected disciplines.
Because FERSMEK's team includes both automation engineers and software developers, we understand both sides of the integration challenge. We can read PLC data structures, configure OPC-UA servers, build REST API connectors, and develop the dashboard and reporting layer — without needing a separate IT integrator to translate between disciplines.
WMS / AGV Control
Real-time material flow management using FERSMEK's WMS/RCS platform. Manages NYTTI AGV fleets, Cappsel storage, and Pesmel ASRS — all linked to your warehouse management system. Inventory movements triggered automatically by production events.
MES Integration
Production tracking, OEE dashboards, work order dispatch, and quality record capture — all pulled directly from the machine. Real-time data fed to your ERP replaces manual shift reporting and spreadsheet tallying.
Custom Digital Platforms
Off-the-shelf software rarely fits the complexity of a custom production environment. We design and build bespoke industrial applications — operator portals, IIoT dashboards, mobile field apps, and reporting tools — purpose-built for your operations.
Pillar 01
WMS / AGV Control
FERSMEK's WMS/RCS platform orchestrates autonomous material flow — from inbound receiving through storage to production line delivery. Tight integration with NYTTI AGV fleets means material moves on demand, not on schedule.
Inbound Receiving
Scan-to-confirm receiving workflows, auto-putaway rules, and quality hold flagging integrated with ERP purchase orders.
Task Orchestration
Real-time task queuing for AGV fleets — dynamic re-routing around obstacles, priority overrides, and zone locking for safe human coexistence.
ERP / MES Sync
Bi-directional inventory updates with ERP on every movement. Production consumption triggers restocking automatically, without manual requisition.
NYTTI AGV Dispatch
Fleet management for NYTTI autonomous guided vehicles — charging cycle management, mission assignment, traffic control, and fleet health monitoring.
Inventory & Traceability
Location-level inventory accuracy across pallet, tote, and unit levels. Full movement history for quality traceability and audit readiness.
Reporting & Analytics
Throughput, dwell time, pick accuracy, and AGV utilisation dashboards. Exportable to BI tools or surfaced in operator portal.
Pillar 02
MES Integration
Connect PLC and machine data to production management systems — so OEE is calculated from actual machine signals, work orders flow from ERP to the machine HMI, and quality records are captured automatically at the point of production.
Work Order Dispatch
Production orders pushed from ERP to machine HMI — operators confirm receipt, not data entry. Work order status reflected in ERP in real time.
OEE & Downtime Logging
Availability, Performance, and Quality calculated from machine signals — not paper forms. Downtime events categorised by operators at the machine in real time.
Quality Records
SPC data, inspection results, and non-conformance records captured automatically and linked to the production order and batch for full genealogy.
Production Scheduling
Sequence-aware scheduling integration — capacity constraints from the floor feed back to planning, reducing the gap between planned and actual output.
Line Sequencing
Assembly line sequencing from ERP customer orders to machine-level job queues. Mixed-model production with automatic changeover instructions to operators.
Real-Time Dashboards
Live OEE, throughput, and shift performance dashboards for operators and supervisors — replacing manual tally boards and end-of-shift reporting.
Pillar 03
Custom Industrial Digital Platforms
Off-the-shelf software rarely fits the complexity of a custom production environment. We design and build bespoke industrial applications — from operator portals that mirror your exact machine layout to mobile maintenance apps that work offline in the plant. Every platform is built by engineers who understand the process it serves.
Operator HMI Portals
Web-based operator dashboards that run on any browser — large control room displays, panel PCs, or operator tablets. Designed with operators, not around a software template.
IIoT Data Dashboards
Aggregate data from PLCs, sensors, and edge devices into unified dashboards. Real-time and historical views, with configurable alerting for out-of-spec conditions.
Mobile Field Apps
Maintenance round apps, work permit workflows, and inspection checklists designed for use in the plant — including offline capability for areas with poor network coverage.
Digital Twin Interfaces
Visualisation layers over live process data — 3D or 2D plant representations that show real-time equipment state, helping operators identify issues before alarms trigger.
Reporting & BI Tools
Automated production reports, shift handover packs, and management dashboards. Data pulled from MES, WMS, or historian and delivered on schedule or on demand.
Legacy System Modernisation
Retire ageing HMI or SCADA software by building a modern web-based interface over the same PLC — extending equipment life without replacing the proven automation layer.
Technology Stack
Our Development Process
Discovery
Map existing data sources (PLCs, sensors, ERP), define KPIs and workflows to capture, and document requirements with IT, operations, and end users.
Architecture
Design the data model, integration protocol selection (OPC-UA, MQTT, REST API), application stack, and system architecture. Review with client IT security team.
Development
Build connectors, configure MES modules, develop dashboards and application interfaces. Staged build with client review at each milestone.
Integration Testing
End-to-end testing against live or staging PLC environment. Data accuracy validation, failure mode testing, and user acceptance testing with operations staff.
Go-Live & Support
Production cutover with FERSMEK team on-site. 3-month hypercare support period with priority response for critical data pipeline and application issues.
MES Rollout Across 4 Assembly Lines — OEE Visibility from Zero to Real-Time
An electronics contract manufacturer needed production counting, downtime logging, and OEE reporting across four SMT and final assembly lines — but had no data infrastructure beyond manual tally sheets. FERSMEK configured OPC-UA data extraction from existing Siemens and Omron PLCs, deployed an Ignition-based OEE dashboard, and built a work order dispatch interface to the client's ERPNext instance. The project was phased by line, with each going live sequentially to allow operators to adapt. Downtime categorisation rules were developed with the operations team in workshops before go-live.
Frequently Asked Questions
Related Services
Purpose-Built Industrial Software, Without the Enterprise Price Tag
FERSMEK builds the integration layer and the applications that sit on top of it. Stop entering production data manually. Start making decisions from real data.