SCALEX Manufacturing Execution System Deployment
Digital Production Architecture for EV Manufacturing
Client Context
The client operates a dedicated electric vehicle manufacturing facility producing battery packs and assembled vehicles across multiple production lines. The facility runs continuous multi-shift production with high expectations for quality traceability, production visibility, and enterprise data integration.
As production volumes scaled, the absence of a unified execution layer became a significant operational constraint. Data was distributed across machines, manual records, and disconnected systems — making real-time production visibility and genealogy tracking difficult to achieve consistently.
Operational Challenge
EV production involves numerous automation-controlled assembly stations, quality checkpoints, and operator interactions across both battery pack and vehicle assembly lines. Without a centralised execution platform, the plant faced compounding operational gaps:
- Limited real-time visibility into production status across multiple assembly lines
- Difficulty tracking component genealogy and vehicle build history
- No centralised production data environment for analysis and reporting
- Fragmented operational data spread across machines, manual logs, and disconnected systems
- Manual tracking of quality inspection results, defects, and rework events
Solution Approach
Our team designed and implemented a full-scope Manufacturing Execution System (MES) platform that connected machine signals, shop-floor automation systems, and enterprise workflows into a unified operational data environment.
The platform was deployed across all production lines — battery pack assembly and vehicle assembly — with dedicated execution instances for each line and a centralised data layer supporting analytics, reporting, and enterprise integration.
The system was integrated with existing automation equipment and enterprise planning systems, enabling real-time data flow from the shop floor to management without requiring manual data entry or end-of-shift reconciliation.
Operational Capabilities Delivered
The platform delivers integrated production management across quality, traceability, performance, and enterprise coordination domains.
Production Order Execution
Manages the execution of production orders across assembly lines — sequencing jobs, tracking completions, and confirming output in real time.
Performance Monitoring
Monitors equipment availability and line performance across all production areas. Live dashboards display shift performance, downtime events, and operational KPIs.
Quality Traceability
Captures quality inspection results at each assembly station. Defects, rework events, and quality outcomes are recorded and linked to the specific unit and build record.
Component Genealogy
Maintains a complete build history for every vehicle and battery unit — recording which components were used, which stations were completed, and when each operation occurred.
ANDON Alerts
Live ANDON displays across the production floor surface operational alerts, line anomalies, and equipment events — enabling supervisors to respond without requiring manual floor walks.
Enterprise Integration
Operational data — production completions, quality holds, and material consumption — is synchronised with enterprise planning systems in real time, eliminating end-of-shift reconciliation.
Material Tracking
Tracks raw material consumption and work-in-progress inventory across production stages, maintaining accurate operational records throughout the assembly process.
Operations Intelligence
Production data feeds analytics dashboards that provide throughput analysis, quality metrics, downtime reporting, and shift performance summaries for plant leadership.
Business Impact
- Real-time production visibility across battery and vehicle assembly lines
- Full genealogy tracking for every vehicle and battery unit produced
- Improved traceability for quality investigations and analysis
- Centralised production data environment for operational analytics and reporting
- Live integration between shop-floor operations and enterprise planning systems
System Architecture
Integrated Production Intelligence Architecture
Layer 1 — Shop Floor Equipment
Layer 2 — OPC-UA Communication
Layer 3 — MES Applications
Layer 4 — SQL Database
Layer 5 — Enterprise Integration
Hover over any layer to understand how production data flows from shop-floor equipment through the MES platform to enterprise systems.
*Project experience represents prior industrial deployments delivered by members of the Iteranium engineering team across global manufacturing environments.
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