MES — Operator Terminal, Live OEE and Andon

1. What MES is for

MES (manufacturing execution) connects the shop floor to the office. The operator at the machine starts, pauses and finishes the job from a terminal; who did what, when, on which operation and for what reason is recorded. From these records come live OEE, the daily production board, downtime and scrap Pareto, Andon calls, the shift handover report and the operator/shift/machine efficiency scorecard.

The window has seven tabs: Production board · OEE · Pareto · Andon · Shift handover · Efficiency scorecard · Definitions. The operator terminal is a separate window (Operator terminal) and its full-screen address is /terminal.

2. Setup: station, token, operator

Add a station (Definitions › Stations): choose a name and the linked machine. If you leave the code empty it is taken from the document series (IS001, IS002…).
Generate a token: the token is shown only once; it is entered on the terminal device together with the station code and kept on the device. Generating a new token invalidates the old one and the open sessions on that station.
Operators prove their identity with their Human Resources › Employee portal account (registration number + PIN). Five wrong PINs lock the account for 15 minutes (the portal rule as is). If the name on the production employee card equals the HR first and last name, labour and piece-rate pay are written to that card.
The terminal device signs in with its own HNR user (recommended: a station account with the mes_terminal permission). Stock movements and confirmation gates run with this account's authority; the operator identity is read only from the terminal session opened with the PIN.

3. Operator terminal

The terminal is drawn for a touch screen with large buttons (at least 64 pixels). When idle it shows the My jobs today list (the official APS schedule for this machine, otherwise the work-order due-date order) and a QR field. Tapping a job or scanning its code starts it.

Button	What it does
Start	Stamps "I started" on the operation (the same field as Stuck Work, the first stamp is kept). If there is an open hold it is refused with `BLOKE_ACIK`. One job runs on a station at a time.
Pause	Asks for the downtime reason. A machine downtime record is opened; APS sees the machine as closed in its next calculation. Depending on the reason an Andon call and a Stuck Work hold are suggested.
Resume	Closes the downtime with its real duration; the job continues where it left off.
Finish / report quantity	Enter the good quantity, the rework quantity and scrap with a reason code; if "This operation is complete" is ticked the operation is closed. Net running time (pauses excluded) is calculated automatically.
Start / end downtime	Station downtime while no job is running (breakdown, no material, break…).
Andon	Calls maintenance, warehouse, quality or the foreman (see section 5).

4. Confirmation and gates

Finishing on the last operation (or on a work order with no operations at all) writes the existing production confirmation: the good quantity is received into stock, components are consumed, labour and piece-rate are calculated and the selected mould's shot counter increases. Intermediate operations do not write a confirmation — so that the product does not enter stock twice, their quantity and time are kept only in the MES record.

Confirmation gates run unchanged. For the four gates whose escape does not need an administrator (negative stock, waste overrun, plan overrun, expiry date) the terminal shows the gate text and resends with the operator's explicit approval ("I approve …, send again"); the approval trace is written on the confirmation. Gates for hold, competence and administrator approval cannot be passed from the terminal — the supervisor confirms from the desktop. When a gate refuses, the station stays running.

5. Downtime and scrap reason codes

Downtime reasons form a tree: Planned (break, planned maintenance, meeting, no planned production) and Unplanned (machine breakdown → mechanical / electrical, no material, mould change, adjustment, quality, no staff, other). Planned downtime is not deducted from OEE availability. Each reason can carry an Andon type and a Stuck Work reason code; scrap reasons are grouped into the 5M classes (material, machine, operator, method, measurement). On the Definitions tab you add codes, deactivate them and add the plastics / metal / textile / food sector templates with one button.

6. Andon call

The red Andon button on the terminal calls one of four teams: maintenance, warehouse, quality, foreman. The call number comes from the document series (AN2026000001) and goes out as an urgent HNROS message. Recipients are the users in Definitions › Andon recipients; if that field is empty, users with the related permission (maintenance: machine cards, warehouse: warehouse, quality: quality system, foreman: production planning) and the order's owner are informed, and if there is nobody, the administrators. On the Andon tab a call is accepted (response time = acceptance − opening) and closed with a resolution note. Open calls appear in the "Attention" area of Pulse.

7. Live OEE

OEE = availability × performance × quality. Availability = running time ÷ (running time + unplanned downtime); performance = ideal time × total quantity ÷ running time (the ideal time is the unit time of the operation in the routing; at most 100% is used in the OEE product); quality = good quantity ÷ total quantity (total = good + rework + scrap). Example: 480 min planned time, 60 min downtime, 1 min/unit ideal, 380 units, 20 scrap → availability 87.5%, performance 90.5%, quality 94.7%, OEE 75.0%.

This measure is single-sourced with the Reports › Production › Machine utilisation and OEE report: both call the same calculation and give the same number for the same period. Live mode shows the current shift from its start until now; "Unrecorded time" is what remains of the elapsed shift after running and downtime are deducted and is not explained by any event (it does not enter OEE, it is made visible). The breakdown can be machine, station, shift, day or operator.

8. Production board and TV mode

The board draws a card for every machine: status colour (green running, amber paused, red down, grey idle), operator, today's OEE, the number of open Andon calls and today's order sequence (planned time, produced / planned, kit %, overdue badge). The kit percentage is the share of the order's remaining component lines that current stock can cover (the material-kit preparation flow is a separate job; here it is only shown). TV mode takes the board full screen (large type for 1920×1080) and refreshes every 10 minutes.

9. Downtime and scrap Pareto

The Pareto tab ranks the largest losses: for scrap the breakdown is reason, machine, product, operator or week; for downtime reason or machine (planned downtime can optionally be included). Rows within the cumulative 80% are drawn with a dark bar. Below, the top 5 scrap reasons of every week are listed. Product scrap is the quantity reported on the terminal with a reason code; scrap cards in the confirmation are kept in another unit and are not summed here.

10. Shift handover

The shift handover gathers everything that happened in a shift on one page: finished operations, jobs left half-done and still running, downtime, scrap, rework, Andon calls and handover notes. A note is written "to the next shift"; the next shift's handover page shows the previous shift's notes at the top. The PDF button converts the report to PDF through the message service (if the service is down, print from the browser). Shifts come from the HR shift definitions; if there are none, 08-16 / 16-24 / 00-08 is used.

11. Efficiency scorecard and piece-rate bonus

The scorecard gives running time, good quantity, scrap, units/hour, scrap % and OEE by operator, shift or machine. In the operator breakdown piece-rate bonus = piece rate × confirmed good quantity (last operation; the same part is not counted again on intermediate operations) and it is calculated only for staff whose pay type is piece rate. The piece rate is read from the Production › Employee card and is the same basis as confirmation labour — piece-rate staff get only quantity on the confirmation, hourly staff only time. The source is the terminal finish records.

12. On a phone

On a narrow screen the MES window becomes three tabs: Terminal (the same terminal — pairing, PIN, job selection, large buttons), Andon (open call cards for the supervisor, accept / close) and Board (machine cards in one column). Scanning with the camera needs the browser's BarcodeDetector support and HTTPS; otherwise use a hand scanner or type the code. The terminal does not work offline.

13. Permissions

Permission	What it opens
`mes`	MES boards (users with the production module also see them)
`mes_terminal`	Operator terminal device account
`mes_tanim`	Definitions of stations, tokens, reason codes, Andon recipients and the OEE target

14. Messages

Code	Meaning and what to do
`MES_ISTASYON_MESGUL`	A job is running on the station; finish it first (double start is blocked).
`MES_OP_BASKA_ISTASYONDA`	The operation is running on another station.
`BLOKE_ACIK`	The order has an open hold; resolve it in Stuck Work.
`MES_JETON_GECERSIZ`	The station token was renewed or is wrong; get a new token in Definitions and pair the device again.
`MES_TERMINAL_OTURUM`	The terminal session dropped (4 hours idle, 12-hour cap or server restart); sign in again with the PIN.
`EKSI_ONAY_GEREKLI` …	A confirmation gate; the terminal shows the approval button or the supervisor confirms from the desktop.

Related guides: Production · Stuck Work · Production Schedule (APS) · Work Centres · Reports · Mobile.