Operator Terminals, Order Board, Travelers and Scrap Reporting — Built Into Synesis MES
A production plan is only as good as the information that comes back from the floor. Synesis MES now includes a complete shop floor control layer: a touch-screen terminal at each station where operators sign in with badge and PIN, an Order Board that shows exactly where every open order is in its route, printable travelers that move with the parts, and scrap reporting by reason, station and operator. It was designed with input from production planners and SAP Business One consultants who run shop floors every day, and it shares one database with the rest of the MES.
One record, two doors. Supervisors and planners post from the office; operators post from the terminal. Both write the same production transactions against the same work order operations, so there is no second system to reconcile and no end-of-shift re-keying. The moment an operator reports a quantity, the Order Board, the work order, the scrap report and the dashboards all show it.
Badge + PIN · Kiosk Mode
A paired tablet or PC at each station runs a full-screen kiosk built for gloves: large buttons, no menus. Operators scan their badge, enter a PIN and see the queue of released operations at their station — or scan a traveler to open an order directly.
Labor Clock · Good · Scrap
Start an operation and the labor clock runs for that operator; stop it and the hours post, rounded up to the minute. Report good quantity, scrap with a reason, issue material and add notes. A clock left running past twelve hours asks for the real hours instead of charging a night.
Where Every Order Stands
Needs Release, In Process, Queued and On the Floor at a glance, with the current station, the route with each step's status, quantity done and due date. Supervisors release steps by hand from here for stations with a manual release rule.
Code 128 · Printable
Print the traveler that goes with each work order: part, quantity, due date and every operation with its station, headed by a Code 128 barcode of the order number that operators scan at the terminal.
By Reason, Station, Operator
Every scrap posting with its reason code, order, operation, station, operator and terminal. Filter by reason to see where scrap really comes from — damaged in handling, tooling, setup, operator error — and feed the dashboards and your quality system.
On Complete · In Process · Manual
Each work center decides when the next step is released: when this one completes, as soon as it starts (for overlapping steps), or only when someone presses Release. Releasing the work order releases its first operation; released steps are never un-released.
Against a Work Order or Ad-hoc
Supervisors without a terminal post completed quantity, scrap and hours against a work order operation, or record ad-hoc work done at a station — with start and end times and the duration calculated automatically.
Work Centers · Operators · Terminals
Work centers with release rule and SAP work-center code; operators with badge, PIN, lock-out and unlock; paired terminals with pairing codes and optional pinning to one station; and the scrap reasons offered on the floor.
Operator · Office · Management
Every employee is classified as Operator, Office or Management. Only operators get terminal access, so badges and PINs are managed where they belong and office staff never clutter the floor.
Synesis MES works alongside SAP Business One: work centers carry their SAP code, and ERP Data Connect brings SAP production orders, purchase orders, goods receipts, deliveries, batches and returns into the MES for reference. For SAP customers that means the production and shop-floor layer SAP Business One does not provide, from the same partner that implements and supports their ERP. Manufacturers without SAP get a complete, working shop floor on its own.
Shop floor control is one module of the MES and can be turned on or off per customer: a plant that only needs terminals and travelers starts there, and adds scheduling, engineering data and analytics when it is ready.
Each terminal is paired once with a one-time code from the MES. After that, operators sign in with their badge (scanned or typed) and a PIN. The session is tied to that terminal and signs out automatically after a few idle minutes, and repeated wrong PINs lock the operator until a supervisor unlocks them.
See the queue of released operations at the station or scan a traveler barcode, start and stop the labor clock, report good quantity, report scrap with a reason, issue material, add notes and release the next operation when the station's release rule is manual.
Each work center has a release rule: on complete (the default), on in-process for overlapping steps, or manual. Releasing a work order releases its first operation.
Yes. Terminals write the same production transactions as the office Report Production form, tagged with the terminal, so the Order Board, work order progress, scrap reports and dashboards update the moment an operator reports.
Watch an operator sign in, start an operation, report good parts and scrap, and see the Order Board update — in a live Synesis MES demo.
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