MES Platform for Real-Time Production Control in a Ready-Meal Factory

We designed and are now delivering a modern Manufacturing Execution System (MES) for a high-volume ready-meal producer, fully integrated with IoT weight-collection devices, barcode scanners, and label printers.

Introduction

The client is a fast-growing ready-meal producer with strict operational requirements, large production volumes, and HACCP/ISO 22000 compliance needs. Their existing workflow relied heavily on manual paper processes, leading to inconsistencies in weight tracking, raw-material usage, shift accounting, and quality control. We were engaged to design and develop a full MES platform covering production planning, shift operations, real-time weight capture, barcode-based traceability, and automated reporting — with seamless integration of IoT devices across the production floor.

Business Challenges

Zero visibility across production and shift operations

Lack of traceability and compliance tools

High operational losses from inaccurate weights and human errors

We conducted onsite interviews, shadowed shift supervisors, and mapped the full production cycle — from warehouse inbound to packaging. Together with the internal analyst, we decomposed all workflows into structured digital processes.

Process

Discovery Phase

Our system architect developed the platform architecture including:

• Real-time connection with industrial weighing devices
• Barcode-scanner workflows for batch tracking
• Label printing automation for semi-finished and finished goods
• IoT event processing pipeline Scalable backend infrastructure for data-heavy operations

Architecture & Engineering

We redesigned all shift tools:

• Digital leftover confirmation at shift start
• Raw-material acceptance workflows
• Task execution with weight compliance control
• Automatic batch numbering & traceability
• End-of-shift reporting with deviations

Shift operations digitalization

Results

Significant reduction of manual work

Paper logs and manual reporting were replaced with streamlined digital workflows, saving supervisors 1–2 hours per shift.

Improved compliance with HACCP & ISO 22000

Digital traceability, incident tracking, and shift accountability support food-safety audits and regulatory requirements.

Integration with IoT scales ensures that every production step is validated, preventing overuse of materials and catching deviations immediately.

End-to-end digital traceability

Every raw material, semi-finished product, and finished item is traceable through batch numbers, barcode labels, and weight logs.

Real-time weight accuracy and reduced losses

Would you like to discuss your project?

We will help you grow your business by creating and implementing a technology strategy tailored to your needs.