Discovery to Optimize.
Gated, not hoped.
Five phases, each with an explicit exit gate. From Discovery through to Optimize, our phased rollout methodology — with change management and stakeholder adoption built into every wave — is why our MES implementations stay live for a decade, not a quarter.
We start on the shopfloor, not in a meeting room. The goal: an honest read of operational maturity, the pain that actually costs money, and the right first site.
Shopfloor walkthroughs
Gemba with operators and supervisors — where data is born and where it dies.
Maturity assessment
Connectivity, data quality, process discipline, and readiness across candidate sites.
Value-case framing
What the program is worth, in operational terms an Operations Director will defend.
Lighthouse selection
First site picked for representativeness and replication potential — not convenience.
Requirements engineered to build from, not to present. Master data is the bottleneck of every MES program — we treat it as the main design artifact.
Functional requirements
Documented to the level needed for build — screens, rules, exceptions, integrations.
Master-data design
Equipment, materials, BOMs, recipes, lot logic — modeled to survive multi-site rollout.
KPI definition
OEE, loss tree, quality — defined precisely enough to be auditable later.
Architecture & template
Integration contracts up to ERP and down to machines. Global core vs. local config.
TrakSYS configured against the spec, machines connected, ERP integrated — and tested with real production data before anyone calls it done.
TrakSYS configuration
Core template built and configured — workflows, screens, events, quality.
Machine connectivity
OPC UA, MQTT, legacy protocols. PLCs and historians integrated to L3.
Enterprise integration
ERP, LIMS, WMS, CMMS — bidirectional, with master-data alignment.
Test with real data
End-to-end runs on actual production scenarios, not synthetic demos.
Go-live is an operational event, not an IT event. We commission line by line, train at the station, manage MES validation requirements where applicable, and stay through hypercare until the site runs without us.
Commissioning
Line-by-line cutover with rollback criteria defined before we start.
Operator training
At the station, on real work — not in a classroom with slides.
Go-live support
Floor presence through the first full production cycles, every shift.
Hypercare
Issues triaged daily; fixes deployed; adoption measured, not assumed.
A live MES is the starting line for operational excellence. Now the data works: OEE improvement routines, loss intelligence, continuous improvement — and the multi-site rollout template carries these gains forward to the next site, better than before.
OEE & loss routines
Daily management built on attributed losses, not back-filled spreadsheets.
Continuous improvement
Kaizen cycles fed by execution data — measured, prioritized, closed.
Template evolution
Improvements flow back into the global core under change control.
AI enablement
Where the data backbone is ready: decision support, root-cause, prediction.
Roughly twelve weeks
to a live first site.
Indicative for a lighthouse factory of typical complexity — actual duration depends on connectivity, master-data state, and integration scope. Multi-site global template rollouts typically accelerate from wave two onward as the template matures. Discovery tells us which.
Adoption is the deliverable.
A configured system nobody uses is a failed project with good documentation. We measure operator adoption, not just uptime.
We stay until it runs without us.
Hypercare ends on evidence, not on a date. The exit gate is a site that no longer needs us in the room.
Honest gates, even when it hurts.
If a gate isn't met, the phase isn't done — and we say so. Slipping a week beats living with a broken master-data model for a decade.
Every program starts with a 30-minute conversation.
One operational pain point, an honest read on what it would take to fix it. If we're not the right fit, we'll say so.