🏗️ Nova MFG – Project Document for Development
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Nova MFG – Project Document for Development

Background

Appomax is building a Nova Manufacturing package – a modular, open, and scalable MES built on Ignition by Inductive Automation, with a SQL backend and a custom Python package (mes_core).

The MES Starter provides the essential foundation for manufacturers to begin digital transformation with core MES functions:

  • Master Data Modeling (ISA-95 hierarchy: Enterprise → Site → Area → Line → Cell)

  • Work Order Management & Scheduling

  • OEE (Overall Equipment Effectiveness) Monitoring

  • Downtime Tracking & Analysis 

Scope

Firat will complete the remaining development tasks, focusing on:

  1. UI Development (Ignition Perspective)

    • Operator Dashboard (control, downtime, reject parts, OEE visualisation)

    • Admin Pages (work orders, scheduling, configuration, production model)

    • Analysis Dashboards (OEE, downtime Pareto, hourly/shift production, monitoring)

  2. Integration & Testing

    • Validate connections between UDTs, Python functions, and the SQL schema.

    • Execute backend and UI test scripts defined in the Bootcamp.

  3. Documentation & Packaging

    • Operator and Admin user guides.

    • Developer/maintenance documentation.

    • Deployment and setup instructions.

    • Demo project preloaded with sample data for customer presentations.

What Has Already Been Achieved

✅ Database Layer (mes_core schema)

  • Tables: enterprise, site, area, cell, line, productcode, productcodeline, run, schedule, statehistory, statereason, counttag, counthistory, counttype, notes.

✅ Python API (mes_core)

  • OEE Functions: calcQuality, calcAvailability, calcPerformance, getOee

  • Work Orders: addProductCode, updateProductCodeLineStatus, addWorkOrderEntry, updateWorkOrderEntry

  • Run Management: calcFinishTime, updateRun

  • State Tracking: storeStateHistory

  • Logging & Count History

✅ UDTs & Namespace

  • Line UDT with OEE-Downtime, Dispatch, Counts

  • ISA-95 Structured Namespace (Enterprise → Site → Area → Line hierarchy)

Functions Implemented (Backend)

  1. Master Data & Filters: Load enterprise/site/area/line IDs, filter objects

  2. Work Order: Add/update product codes, assign to line, create/update WOs

  3. Run: Calculate estimated finish time, update run metrics

  4. OEE: Quality, Availability, Performance, OEE; downtime seconds; counts

  5. State: Track state history (storeStateHistory)

  6. Counts: Store and retrieve production counts

  7. Logging: Event logging

UI Pages to be Developed

Admin Pages

  1. Production Model (Main)

    • ISA-95 hierarchy management (Enterprise/Site/Area/Line)

    • Line/unit configuration (enable/disable, rate, setup mins)

  2. Work Orders (Main)

    • List all WOs with status, product code, schedule/run links

  3. Create Work Order (Popup)

    • Input WO number, product code, quantity

  4. Schedule Work Order

    • Select line, set start/end, assign rate/setup, estimate finish time

  5. Configurations

    • Manage product codes, downtime reasons, count types, etc.

Operator Pages

  1. Operator Control (Main)

    • Start/stop run, pause/resume, select work order

    • Categorise downtime, reject parts (scrap reasons)

    • Display real-time OEE, counts, cycle time, utilisation

  2. Edit Downtime (Popup)

    • Categorise downtime reason (Planned/Unplanned)

    • Add notes, filter/search downtime events

Analysis Dashboards

  1. OEE Dashboard

    1. OEE breakdown (A/Q/P), per run/shift/day

  3. Downtime Pareto

    1. Top downtime reasons, Pareto analysis, time filters

  5. Production by Hour / Shift

    1. Actual vs Standard throughput trends

  7. Monitoring

    1. Real-time machine/line status, alarms snapshot

UI Shell / Utilities

  1. Navigation Administration (Nav Tree)

  2. Shared UI Components (Header, Time, Logged-in user, Value indicators)