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 industry-proven 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.
Offline preparation plus window switching: servers, database and software are cut over inside planned maintenance windows — typically 1-2 shifts depending on complexity — with live data migrated without stopping the line.
Full migration with consistency checks, including database version upgrade and schema conversion. Traceability chains stay intact and old batches remain queryable.
Server hardware and OS, database, generational application upgrade, network and clients, plus OPC-UA and other interfaces — a vertical refresh from platform to application.
The upgrade follows the OEM system’s own upgrade path, keeping process flows and UI logic so operators do not need to relearn the system.
Site assessment and full backup first, test-environment validation and parallel running, phased cutover and a documented rollback plan, with two-person verification at critical steps.
3-5× faster reports and queries, improved availability and security, shop-floor visualisation and KPI boards — and a data foundation for AI-SOP vision and other perception layers.
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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