The New Standard of Production.
One operating system for every machine in your plant — from the raw material store to the truck, with AI that checks every cycle and every part.
Raw material store
Every bag and coil is scanned in at goods receipt and put away to a known rack. Moulding is issued the oldest stock first.
- Receipt by scan — no manual register
- Stock by rack, age and lot
- First-in, first-out to the machines
Moulding shop
Four machines, four real states. MOS reads each controller, so the screen says what the machine is actually doing — and why.
- M-01 running — OEE live from the controller
- M-02 breakdown — seen at once, maintenance called, MTTR running
- M-03 changeover on a work order · M-04 idle with its reason
Utilities & energy
Energy and compressed air are read from the LT panel and every machine panel, so cost is known per machine, per shift and per part.
- kWh by machine, line and shift
- kWh per part — not a monthly bill
- Compressor load, pressure and leak hours
DOJO & skill matrix
New joiners learn and are certified in the DOJO before they touch the line. Certification feeds the skill matrix that decides who runs which station.
- Certified before the line
- Skill matrix kept current by results
- Coverage per shift, gaps planned
Control room: work orders & masters
A planner releases a work order. The model’s masters — BOM, routing, test limits, label format — reach every station in seconds, and the line runs the new model.
- Work order to running line in seconds
- One master per model — no station set up by hand
- Live OEE, energy, breakdowns and output vs plan on the wall
Pasting & assembly
A dispensing robot lays the glue bead on every part. At assembly the station camera checks every step against the taught standard, and face ID confirms a trained operator.
- Bead on every part, presence checked
- Every assembly cycle checked: OK, SLOW or NG
- Only a trained operator at the station
Scan & interlock
Every serial is scanned. A unit that missed a stage — here, one with no glue bead — is stopped by the barrier and pushed to the hold table.
- No skipped stage reaches the next station
- Held units can be released only by an allowed role
- Every hold recorded with its reason
AI validation
A camera judges every unit in under a second. OK units move on; NG units go down the spur to the repair station.
- Every unit judged — not a sample
- One reason, defect circled on the picture
- NG never mixes back into good stock
Repair station
NG units arrive red-tagged and stay held on the repair rack. The repair screen shows the reason and the rework steps; a camera re-inspects before the unit rejoins the line.
- Held until fixed — never lost
- Reason and rework steps on screen
- Re-inspected before it returns; history kept
Testing
The leak-test hood comes down on every unit; the result is read from the bench and stored against the serial.
- Test results read, not typed
- Stored against every serial
- A failed test cannot be packed
Packing & palletising
Each unit is packed and labelled; the label carries its history. A robot stacks eight cartons a pallet, every carton counted.
- Label printed at the right station
- Carton → pallet link recorded
- Counts that match the plan
Warehouse & ASRS
The stacker crane puts each wrapped pallet into a free cell. MOS knows what is in every cell and sends the oldest out first.
- Occupancy cell by cell
- FIFO out to dispatch
- Stock is the sum of scans
Dispatch
Pallets leave through the RFID dock gate into the truck. Each is read, the lamp shows the move was allowed, and the truck’s load is known pallet by pallet.
- Every pallet read at the gate
- Pallet → truck link for every dispatch
- Wrong or unapproved moves held
Safety
A camera watches the path to every hydrant through a virtual line. A trolley left in the way alerts the area in-charge and escalates until it is clear.
- Obstruction seen in seconds
- Escalation level by level, up to WhatsApp
- Time to clear recorded
Where MOS is installed
Every cyan ring is MOS hardware: gateways and energy meters in machine panels, scanners, cameras, RFID readers, station terminals — and one plant server in your server room.
- Machines are not modified
- Everything runs inside the plant network
- Only outbound connections — no port opened
One operating system
Every area you walked through reports into one system — on a server inside your plant, with a copy for management. That is MOS.
- One login, one database, every area
- Works when the internet does not
- Proven on your own machine first