Software + hardware upgrade and retrofit of the Manufacturing Execution System (MES) and shop-floor visualization & data-analysis system — originally from a world-leading German technology supplier — with zero data loss and a smooth, minimal-downtime cutover.
We respect and preserve the original German factory system. We only perform a generational upgrade — running this battle-proven industrial software on modern platforms and hardware.
Not starting from scratch — upgrading a world-class original system to the latest form it deserves.
Two cornerstones of shop-floor digitalization: one commands and executes production, the other turns the live shop state into data you can see, understand and act on.
THE "BRAIN" · MES
Connecting upper-layer ERP with field devices/PLCs, it handles sequencing, tracking, scheduling and process-command dispatch across the entire body journey from line-on to line-off. It decides where each body is, where it goes and what it does.
THE "EYES" · Equipment / Energy / Quality Data Platform
Collecting equipment, energy and process data, it presents line health through real-time screens, trend curves, alarms and reports — the unified window for OEE, energy and downtime analysis.
The diagram shows where the two systems sit in the automation pyramid and the layers the upgrade touches — a vertical full-chain renewal from servers and network to clients.
After a decade-plus in service, both software and hardware are nearing end-of-life, and risks keep mounting.
Running on long-retired OS & database versions with no security patches — exposed to ransomware and compliance-audit risk.
Servers and IPCs run past their service life; after a failure there are no original spares — and downtime costs millions per hour.
Data grows yearly, reports run slower, live screens stutter — unable to support ramp-up or new-model introduction.
The old architecture struggles to integrate MES-to-cloud, energy management and digital twin — data can't get out or be used.
Visible only on fixed terminals; management has no mobile KPIs and abnormal-response is delayed.
Engineers who know the old version are increasingly scarce; knowledge is not passed on and O&M depends on a few individuals.
More than installing a new version — from the underlying platform to the top-layer application, from servers to networks, a vertical end-to-end renewal.
Both original systems upgraded to the current supported major version, enabling new function modules.
Retired legacy OS → current Windows Server / Linux long-term-support versions.
Upgrade the DB engine; historical data migrated with zero loss and performance tuning.
Next-gen real-time screens, OEE/energy dashboards, web and mobile portals.
Standardized OPC-UA / REST interfaces connecting ERP, energy management, digital twin.
Account privileges, network segmentation, audit logs — meeting MLPS and compliance requirements.
New-gen rack/virtualization servers, CPU/memory/storage expansion, dual-machine hot-standby.
All-flash/hybrid storage + automatic backup strategy, safe retention and rapid recovery of historical data.
Gigabit/10G industrial switches, ring redundancy, no single point of failure on critical links.
Full renewal of field operator stations, dashboard large screens and shop-floor IPCs.
Renewal of acquisition gateways, energy meters and RFID readers — higher precision and frequency.
UPS, cabinet cooling and monitoring to ensure 7×24 stable operation.
Visible performance gains, visible risk reduction, visible return on investment.
New hardware + DB optimization, KPI reports respond in seconds.
More precise downtime analysis, fast bottleneck & anomaly localization.
Device-level energy metering provides a solid basis for energy-saving retrofits.
Dual hot-standby + redundant network — no more unexpected line stops.
Phased parallel cutover, completed during planned maintenance.
Full data-validated migration, traceable and auditable.
Back to an original supported version, long-term maintainable.
View production lines & KPIs anytime on phone/tablet.
A mature project methodology that minimizes upgrade risk and shortens line-stop time.
Review system version, hardware inventory, data volume & interfaces; output a feasibility report.
Software/hardware selection, migration route, cutover window and roll-back plan design.
Build the new environment in parallel, trial data migration, full offline validation — no impact on the live system.
Full data migration + commissioning during planned maintenance; switch after dual-system parallel validation.
On-site support, operator training, documentation hand-over and long-term O&M.
Deep understanding of the original system, plus localized rapid-response engineering capability.
Deep mastery of this German supplier's execution & visualization systems — familiar with its architecture, data model and upgrade path.
Mature data validation and roll-back mechanisms; years of historical production data migrated intact and traceable.
Parallel build + maintenance-window cutover to minimize impact on production.
System, server, network and server-room delivered integrated — single point of responsibility.
The upgrade connects to MES-cloud, energy management and digital twin, paving the way for the next step.
Chinese-speaking team, rapid response, on-site support and training — long-term maintainable.
Book a free site assessment — we will produce an upgrade-feasibility report and a preliminary solution budget for your two systems.
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