01
Plan and Floor Disconnected
After a work order is released, input, output and exceptions are counted by hand, so progress lags and timely adjustment is difficult.
RockPlus MES
Manufacturing Execution System
Built around the work order, it unifies routing, track-in/track-out execution, error-proofing checks and traceability records in one system, moving production from "relying on people watching and rules on paper" to "controlled by the system and driven by data."
MANUFACTURING EXECUTION CENTER
Work Order Progress
OrderActivate · SN · Close
RoutingPass / NG branch
ProofingStation switches
TraceSN ⇄ Material lot
Live Track Status · SN 2309280016
LaserPrintSPIMountReflowAOI
Mount · Material checkMaterial not loadedBlocked
Error-proof Block
Wrong material · Skip · Hold
Wrong material · Skip · Hold
Track = Report
Output · Hours auto-logged
Output · Hours auto-logged
Closed-loop Work OrdersFrom creation and SN issuing to close-out
Routing ControlNo production until a route is released
Real-time Error-proofingWrong material, skipped steps and Holds blocked instantly
SN Forward & Backward TraceCustomer return lookup from hours to minutes
Shop Floor Challenges
Shop floor management is about
more than "counting output"
With high-mix, low-volume production and ever stricter customer audits, paper documents, line leader experience and after-the-fact inspection can no longer guarantee that every product is built to process requirements with a complete record.
02
Process Relies on Watching
Routings live in documents, so missed steps, skipped steps and rework outside the route are only found after the fact.
03
Errors Surface Too Late
Wrong materials, mixed orders and products on Hold keep moving, often discovered only at downstream inspection or at the customer.
04
Broken Trace, Hard Returns
Process, equipment, material and test data sit in different systems, so the scope of a quality issue cannot be pinned down quickly.
SHOP FLOOR EXECUTION PLATFORM
Work-order-driven, system-driven execution
It takes production orders from ERP above and connects scan terminals, PDAs, PLCs and test equipment below, turning every track-in/track-out into a verifiable, recorded, traceable fact.
Work Order
Work Order
Work Order
Routing
Routing
Routing
Track-in/out
Track In/Out
Track In/Out
Error-proofing
Error-proofing
Error-proofing
Traceability
Traceability
Traceability
Reporting
Reporting
Reporting
RockPlus MES · Execution Core
ERP Production Orders
Product BOM
Track Records
Material Loading
Test Parameters
Exception Records
Station Scan TerminalPDAPLC Line ControlMounterSPI / AOIICT / FCTProgrammerOther Test Equipment
Core Capabilities
Core Capabilities
Built on four main lines, "work order, process, error-proofing and traceability," it delivers digital control across the entire production execution process.
01 / WORK ORDER
Work Orders
Takes ERP production orders and manages work order status, activation, serial number issuing, material preparation linkage and close-out.
02 / ROUTING
Routing Control
Builds steps, paths and branch conditions by product and version. Routes take effect once released, turning process requirements into system rules.
03 / TRACK
Track-in/out
Triggered by scanning, PDA or PLC line control, with single-unit, panel and batch granularity. Output is reported automatically on track-out.
04 / ERROR-PROOFING
Error-proofing
Material matches position, steps match route, status matches Hold/NG, data is uploaded, quantity matches plan, all configured as switches per station.
05 / TRACEABILITY
Full Traceability
Process, material, equipment parameters, and consumables and fixtures are linked to the SN, with both forward and backward tracing.
06 / BARCODE
Barcode Management
Generates SNs, panel codes, batch numbers and package codes by encoding rules, with label template printing and panel-to-board binding.
07 / EXCEPTION
Exception Handling
Hold containment, defect entry, repair and rework, and scrap approval form a closed loop, and exception status takes effect immediately on track-in/track-out judgment.
08 / REPORTING
Reporting & Dashboards
Summarizes output, yield and man-hours by equipment, work order and shift, supporting shop floor dashboards and daily production analysis.
Work Order Management
Work Orders: Let the Plan Drive the Floor
The work order is the primary document of manufacturing execution. From order intake to close-out, every step has a status, checks and records.
01
Intake & Order Creation
Sync ERP production orders and create work orders bound to product, BOM and line. Supports SMT, DIP, assembly, pre-programming, packaging and coating types; orders can be merged for production or split by batch.
Order IntakeCreate Order
02
Activation & Material Prep
Pending, in production, completed, paused and canceled are all recorded. An order must be active before track-in/track-out, and same-line, same-type orders switch automatically, preventing mixed orders. An SN pool is generated by planned quantity, with material issue and replenishment tasks created automatically.
ActivateIssue SNsMaterial Prep
03
Execution & Close-out
Track-out reports output, and input beyond the planned quantity is blocked automatically. Daily plans and Gantt views by line × shift × date are provided; the system periodically totals last-step good units and closes work orders by rule.
ExecutionClose-out
Process Control
Process Control: Write Process Requirements into System Rules
A routing is no longer just a document. No production until a route is released, an NG judgment automatically takes the rework path, and steps cannot be skipped before prior ones are completed.
Routing Engine
The engine decides the route,
not human memory
At every track-in/track-out, the system calculates from the routing "where to go next" and blocks every non-compliant move.
Process engineers build steps, paths and condition expressions by product and version, and released routes take effect uniformly. At track-in/track-out, the engine combines the current step with the judgment result to give the next step, the rework endpoint, or a block decision.
Routing Illustration · ROUTING FLOW
Step APrint
Step BMount
Test JudgmentOK / NG
Step DNext Step
Pass PathJudged good, the unit moves to the next step per the route and the track record is generated automatically.
NG PathJudged defective, the unit goes to repair and rework automatically, with the rework endpoint checked against the original work order.
Routing
Modeled by product, version and validity period, with draft, lock and release fully controlled.
Step Nodes
Define step order, test steps, maximum test attempts and default defect groups.
Path Branches
Default, Pass and NG paths, with rework endpoint configuration.
Condition Expressions
Select the next step dynamically by judgment and condition, with configurable start and end dates.
Station Spec
Configure control mode and each error-proofing switch by station and equipment group.
TRIGGER
Three Trigger Modes
Station scanning, PDA handheld terminals and PLC line control, fitting both manual stations and automated lines.
GRANULARITY
Three Track Granularities
Single SN, panel and container, or batch Lot, with single-unit and batch modes coexisting in one system.
SKIP & REWORK
Skip & Rework Checks
Skipping unfinished prior steps is blocked by default, legal skips follow route judgment, and rework is fully recorded.
TIMEOUT
Track Timeout Alarm
Detects track-in/track-out timeouts by step interval and raises alarms, exposing stalls and WIP buildup in time.
Error-proofing
Error-proofing: Stop Problems Before They Happen
Five types of checks combine into a station-level error-proofing strategy, configured as switches. Process engineers simply tick them per station in master data, with no code changes.
01 / MATERIAL
Material Match
Reel barcodes are registered to station and slot. Material not loaded or loaded in the wrong position is blocked at track-in/track-out.
02 / ROUTING
Route Sequence
Equipment not on the route, prior step not tracked, or a completed step tracked again are all blocked by the system.
03 / STATUS
Hold / NG Status
Holds at five granularities (work order, batch, SN, part number, material barcode), plus NG, scrapped and shipped units, may never flow on.
04 / DATA
Data Uploaded
If key data such as test records or program version is not uploaded, or consecutive NG reaches the limit, further track-in/track-out is prohibited.
05 / QUANTITY
Quantity vs Plan
Work order not activated, different from the order in production, or input exceeding the planned quantity, the system blocks automatically.
Equipment Interlock: Blocks Act Directly on Equipment
The track-in/track-out interface returns a unified judgment code. In line control mode, the system sends "release" or "stop" commands back to the PLC to control the conveyor, replacing people watching people with equipment interlock.
Material Not LoadedMaterial is not loaded at this step. Please load it first
Prior Step Not TrackedPrior step not tracked. Skipping is not allowed
Hold BlockWork order, batch or SN is on Hold. Flow stopped
Consecutive NG LimitMaximum test NG count reached. No further testing
Work Order Not ActiveCurrent work order is not active or differs from the order in production
Traceability
Full Traceability: Every Product Has a Record from Birth
Fact records are generated at track-in/track-out, automatically linking work order, serial number, equipment, fixtures, materials and test parameters, without after-the-fact entry.
Process Trace
View the full track-in/track-out history by SN, including sequence, in/out times, duration, judgment result, equipment and fixtures.
Material Trace
Each SN maps to the material reels and lot numbers used at every step, and the products that used a material batch can also be looked up in reverse.
Parameter Trace
Equipment and test parameters are stored in a unified "test item, value, limits, result" structure, with photos and files attachable.
Resource Trace
Loading records, usage counts and life of stencils, solder paste, squeegees, fixtures and jigs are linked to products and recorded.
Forward Trace · Full Chain from Product
SN / Box No.Track HistoryEquipment / FixtureMaterial LotTest Parameters
Enter a serial number to reconstruct every step the product went through, every material used, and the raw data of every test.
Backward Trace · Impact from Material
Material Lot / ReelUsed StepAffected SNWork OrderShipment
When a material problem occurs, quickly identify the affected products and work orders, narrowing recall and containment down to the reel.
Terminals & Devices
Multi-terminal & Equipment Connectivity
Choose the connection method that fits the level of automation on the floor, so manual stations and automated lines are managed under one execution control system.
SCAN
Station Scan Terminal
Operators scan at the station to track in/out, load and unload material and enter exceptions, with the interface tailored per station.
PDA
PDA Handheld Terminal
Used for line-side loading and unloading, spot checks, skill lookup and manual track-in/track-out in exceptions, fully recorded.
PLC
PLC Line Control
Reads product information automatically through the PLC to trigger track-in/track-out, and sends back release or stop commands to control the line.
EQUIPMENT
Test & Production Equipment
Connects SPI, AOI, ICT, FCT, X-Ray, mounters and programmers, with test results taking part in judgment in real time.
Application
Typical Applications
Suited to high-mix, low-volume discrete manufacturing with high requirements for process control and traceability.
Electronics Assembly / EMS
Line-wide error-proofing from printing and mounting through reflow to test. Changeovers verify work order, stencil, squeegee and program, so every PCBA has a record from birth.
Automotive Electronics
Meets OEM audit and traceability requirements, with challenge-part release control, OCAP exception handling and shipment production records available on demand.
Power & Module Assembly
Mixed assembly of PCBA and mechanical parts, with process parameters such as press-fit and welding recorded per product, and fixtures bound to products by dual codes.
Multi-site & Line Replication
Shifts, language and business rules are configured per site, so a new line goes from "redevelopment" to "copy plus configuration."
FAQ
Common questions on system integration, error-proofing configuration and traceability.
What is the relationship between RockPlus MES and ERP?
ERP handles orders and master data, while MES handles shop floor execution. MES can synchronize ERP production orders and master data, and report production results back through configured interface routes. Once a work order is created, MES drives shop floor execution such as routing, track-in/track-out, error-proofing and traceability. The specific integration approach is assessed against the open interfaces of the customer's ERP.
Do error-proofing rules require custom development?
Common error-proofing rules are configured as switches in the station specification, such as material loading check, program check, Hold interception, consecutive NG limit and active work order check. Process engineers can enable them per station in master data without changing code. Customized rules can be built on top of this.
How granular can traceability be?
Down to the individual SN. Forward tracing shows the full track-in/track-out history, equipment, fixtures and test parameters by SN; backward tracing finds the affected products from a material batch or reel, enabling fast location of customer returns and abnormal batches.
Can equipment trigger track-in/track-out automatically?
Three trigger modes are supported: station scanning, PDA and PLC line control. In line control mode, the system sends release or stop commands back to the PLC based on the judgment result, achieving equipment-level interlock. The specific integration capability is assessed against how open the equipment is.
Make every track-in/track-out a controlled, traceable production fact
Built around the work order, establish process control, production error-proofing and full traceability, so shop floor execution has rules, records and evidence.
