Plex Systems ERP Software

Plant Floor Control

Be at the center of it all with complete control of your plant floor.

Schedule and track production jobs (work orders) using features such as job templates (a library of process routing options) and job sets (coordinated production of related jobs).

Production operators use Control Panel to perform an array of tasks including recording production in real time, maintaining lot control, collecting inspection data, registering machine status over time, and validating tool and maintenance requirements. Additional functionality includes scrap and rejection tracking, supply (MRO) management, and a plant floor console that displays overall plant floor operational status at a glance.


  • Control Panel

    • The Control Panel is a central feature of most Plex implementations. Most production personnel interact with the system via this unique, highly-configurable and easy-to-use touchscreen-optimized interface.
    • Directly capture setup, inspection, production, maintenance, and tooling hours for labor and workcenter tracking in real time
    • Select production setups from the dispatch list view of the production schedule
    • View bulletins and setup, operation, tooling, and maintenance instructions
    • Collect inspection and SPC data on schedules enforced according to production count, elapsed time, shift change or other conditions
    • Select source inventory subject to configurable lot control rules
    • Recording production automatically maintains lot control and traceability, depletes source inventory and increments tool life data
    • Ensure correct tooling is present at the workcenter
    • Ensure compliance with workcenter and tooling maintenance schedules
  • Job Clock

    • Collect and track labor hours against specific jobs (work orders) via an easy-to-use touch-screen optimized display
    • Display job instructions and other information necessary for production
  • Job Sets

    • Define and track collections of related jobs (work orders), including jobs to produce components or ingredients for top-level jobs in the set.
  • Job Templates

    • Flag any job-specific process routing as an approved process or “template”
    • When scheduling production, select from any existing template routing for that item
    • In addition to routing operations, new jobs will inherit all other characteristics of the template such as required materials and ingredients, quality control plans, etc.
  • Job Tracker

    • Retrieve instructions, track activities, and record production against jobs as they are processed
    • Run multiple jobs simultaneously at a single workcenter
  • Job Tracking System

    • The Job Tracking System is the foundation for production scheduling.
    • Plan, execute and track jobs (also referred to as work orders, shop orders, releases, or other terms) which represent instructions to produce a certain quantity of a certain product by a certain due date
    • Highly integrated with inventory and lot tracking, customer orders, and production requirements planning
    • Can be used in stand-alone mode for simple scheduling conditions
  • OEE Reporting

    • Overall equipment effectiveness (OEE) is a standard and widely recognized indicator of efficiency, quality, performance and availability of production workcenters.
    • View OEE results calculated based on data automatically captured by production interfaces.
  • Plant Floor Console

    This patented technology enables you to:

    • Build an on-screen map of your facility that visually depicts workcenters and storage locations in real time
    • Display current workcenter status by color; for example green may indicate “in production,” yellow may indicate “in setup” and red may indicate unscheduled downtime
    • Click on the workcenter icon to pop up details regarding current status or navigate directly to the control panel
    • Optionally use this interface to change workcenter status and automatically create a workcenter log record, track labor hours and move inventory
  • Production Tracking

    • Track production using reports which provide extremely granular detail or high-level summarization as desired
    • Highly integrated with inventory and lot tracking, tool tracking and scheduling
  • Rejection Tracking

    • Track production using reports which provide extremely granular detail or high-level summarization as desired
    • Highly integrated with inventory and lot tracking, tool tracking and scheduling
  • Scrap Tracking

    • Reduce costs and inefficiency by tracking and analyzing scrap reasons and root causes.
  • Shift Setup

    • Define as many distinct shifts as necessary
    • Specify shift start and end times, breaks and lunch periods
    • Define shift cycles that determine which days each shift is active
    • Set adjustments of production that occurs shortly before or after midnight but should be reported with the next or previous calendar date
    • Apply different shifts based on workcenter, employee, and product
    • Apply overrides to reduce or increase shift times as dictated by production requirements, maintenance or other factors
  • Shop Assignment Screen

    • Display each employee’s assignment for the day on a marquee information screen.
  • Supplies (MRO)

    • Create and maintain a list of standard maintenance, repair and operation (MRO) items such as supplies, tools, materials, and services
    • Easily requisition and re-order these frequently used items
  • Supply Crib Management

    • Manage maintenance, repair and operation (MRO) supplies using an electronic check in/check out system to capture usage transactions and cost
    • Track barcodes of consumable and returnable items
    • Automatically reorder supplies based on flexible inventory parameters
  • Workcenter List

    • The Workcenter List is the master list of production workcenters used by the company.
    • Workcenters may refer to single machines, work cells made of several pieces of equipment, or areas where work is performed by hand
    • Highly integrated with production tracking, scheduling, capacity planning, preventative maintenance, equipment list and many other modules
  • Workcenter Tracking

    • Capture events which occur at a workcenter including production, setup, maintenance and downtime
    • View reports of uptime, availability, overall equipment effectiveness (OEE), and other machine efficiency metrics
  • Disassembly

    • Control and track the conversion of a large item or assembly into a set of smaller discrete components.
  • Heat Treat Manager

    • Plan and record product loads in a heat treat furnace
    • Select inventory to be placed in the furnace based on similarity of heat treat parameters
    • Verify the history of all heat treat data, such as temperature, time, quench, etc.
  • Heat Treat Parameters

    • Manage product-specific parameters and settings for heat treat operations
    • Intended for internal (as opposed to subcontracted) heat treating services
  • Weigh Scale Integration

    • Connect count-by-weight scales directly to Plex Online via serial port connection
    • Eliminate manual key-in and potential for mistakes when recording production, checking inventory or preparing inventory shipments