Our Services
Four practical systems that move manufacturers from paper and spreadsheets to real-time data — designed for Indonesian plants, especially 1st & 2nd tier automotive suppliers serving Japanese OEMs.
Manufacturing Execution System (MES)
A Manufacturing Execution System (MES) is software that tracks production execution in real time on the factory floor — recording what was made, when, by which machine, and where time was lost.
The problem
Production data lives in spreadsheets and operator notebooks. Managers find out about downtime hours after it happened. OEE is a guess, not a number.
What we deliver
- Real-time production order tracking from start to finish
- Downtime capture with operator-friendly reason codes
- OEE (Availability × Performance × Quality) calculated automatically
- Shop-floor screens designed for gloves, glare, and fast input
- Integration with your existing ERP and label printers
Typical outcomes
Downtime visibility within minutes; OEE based on real data; clear ownership of production losses.
Deployed for a Japanese OEM supplier to replace paper production logs across three assembly lines. Daily reporting cycle dropped from next-morning to live.
Computerized Maintenance Management System (CMMS)
A Computerized Maintenance Management System (CMMS) is software that plans, tracks, and records all maintenance activity in a plant — preventive schedules, work orders, spare parts, and asset history in one place.
The problem
Preventive maintenance lives on a wall calendar. Spare parts run out at the worst moment. When a machine breaks, no one can find the last service history.
What we deliver
- Preventive maintenance schedules with automatic work order generation
- Work order tracking with mobile-friendly technician views
- Spare parts inventory tied to assets and consumption
- Asset history and reliability metrics (MTBF, MTTR)
- QR-code asset tags for instant lookup on the floor
Typical outcomes
Fewer surprise breakdowns; spare parts planned, not panicked; full audit trail per asset.
Implemented at a Japanese OEM supplier across stamping and welding lines. Preventive compliance rose from ~50% to 95% in the first quarter.
Digital Checksheet
A Digital Checksheet replaces paper inspection forms with mobile-first digital forms that capture operator entries, photos, and signatures in real time — with full audit trail and instant searchability.
The problem
Paper checksheets fill binders no one reads. Signatures get faked. When a customer audit shows up, finding the right sheet takes hours.
What we deliver
- Mobile-first forms that match your existing paper layouts
- Operator authentication tied to each entry
- Photo capture for evidence and abnormality reporting
- Auto-escalation when out-of-spec values are entered
- Searchable historical records with export to PDF for audits
Typical outcomes
Paperless inspections; instant audit retrieval; abnormalities flagged in real time.
Rolled out at a Japanese OEM supplier for quality wall checksheets. Audit prep time fell from one day to under an hour.
Dashboard Reporting
Dashboard Reporting is the practice of displaying plant KPIs — production, quality, maintenance, delivery — in live, role-specific dashboards instead of weekly hand-assembled Excel reports.
The problem
KPI reports get assembled by hand every Monday morning. Different leaders see different numbers. Strategic decisions wait on data that's already stale.
What we deliver
- Live dashboards for production, quality, maintenance, and delivery
- Shop-floor TV displays with auto-rotation across views
- Role-specific dashboards (operator, supervisor, plant manager, executive)
- Mobile-friendly views for off-shift leadership
- Export to PDF / PowerPoint for board reporting
Typical outcomes
One version of the truth; weekly KPI prep eliminated; faster, data-backed decisions.
Deployed at a Japanese OEM supplier with feeds from MES, CMMS, and quality. Replaced 12 weekly Excel reports with one live dashboard.
Need kanban card printing too?
The Zenban Kanban System is our purpose-built e-Kanban card printer for 1st & 2nd tier automotive suppliers — eliminates the manual cutting and sorting that pushes kanban preparation into paid overtime.
Explore Zenban →
Frequently asked questions
How long does a typical MES or CMMS deployment take? +
A focused pilot on one line or one asset class typically runs 8–12 weeks from discovery to go-live. Plant-wide rollouts follow in phased waves over 3–6 months, depending on scope and the number of equipment integrations.
Do your systems integrate with our existing ERP? +
Yes. We routinely integrate with SAP, Oracle, Odoo, and custom in-house ERPs via REST APIs, scheduled file drops, or database views — whatever your IT team prefers. Integration scope is mapped during discovery so there are no surprises.
Can the system run if our internet drops? +
Shop-floor capture (MES production logs, Digital Checksheet entries, CMMS work-order updates) continues offline on the local server or device. Data syncs to dashboards and ERP once connectivity returns. Production never stops because the internet did.
How are users trained on a new system? +
Training is built into the rollout: short on-shift sessions for operators, deeper workshops for supervisors and admins, and printed quick-reference cards at each workstation. We stay on-site through the first week of live operation to coach in real time.
What happens to our old paper records? +
Historical paper records can be retired in place, archived as scanned PDFs, or selectively backloaded into the new system (typical for audit-critical data like CMMS asset history). We map this during discovery so audit continuity is never broken.