Electronics Factory Enhances Quality and Delivery Efficiency with ESOP and MES Integration

400+ ONERugged Panel PCs Deployed | 100% Digital Operations and Scheduling | 99.5% Process Traceability | 80% Quality Improvement

Client Overview

The client is a leading player in the domestic electronics manufacturing industry in China, specializing in developing and producing consumer electronics like laptops and industrial devices such as rugged tablets. Serving a wide range of domestic and international customers, the company owns an 8,000-square-meter factory with an annual production capacity in the millions. In recent years, they have been steadily advancing their factory's digital transformation toward intelligent manufacturing.

Challenges

As an industry leader, the client faced the dual challenge of meeting the growing demand for diverse product models while maintaining flexibility for small-batch, large-scale production. Rapid market changes and technological advancements put pressure on the traditional manufacturing model, revealing several limitations.

The client's factory previously relied on paper-based SOPs for operational guidance, which were prone to errors and slow updates, leading to inconsistencies across workstations and affecting product quality. Frequent product model switches further complicated operations, requiring additional time for workers to adapt, resulting in bottlenecks in efficiency.

Additionally, the lack of real-time production data tracking made it difficult for management to identify and address anomalies quickly. Small deviations in equipment status or process execution, left unchecked, could compromise product quality. The harsh production environment, including dust and temperature fluctuations, posed challenges for traditional equipment, increasing downtime and maintenance costs. These issues constrained the factory's production efficiency, quality control, and market responsiveness, necessitating a smart production management solution to overcome these bottlenecks.

Solution

To address these challenges, the client implemented a comprehensive digital upgrade by deploying over 400 ONERugged P17A Panel PCs across its production lines. Each workstation was equipped with two tablets seamlessly integrated with MES and ESOP systems, enabling real-time operational guidance and production data management.

The P17A's rugged panel pc design and IP65-rated protection allowed it to operate continuously in harsh conditions, such as dust and temperature variations, minimizing equipment failures and ensuring uninterrupted production.

During the production preparation phase, the MES system generated detailed production schedules upon receiving orders, while the ESOP system automatically created digital work instructions, which were instantly shared with each workstation via Wi-Fi. Unlike paper-based instructions, digital guides could be updated quickly and accurately, eliminating delays or errors in distribution. Operators logged into the ESOP system with their credentials to access task-specific instructions displayed on the P17A's high-resolution touchscreens, ensuring efficient task execution without requiring additional training.

For multi-model production, the MES system dynamically adjusted schedules based on equipment status and material availability, while the ESOP system updated operational instructions in real time. This streamlined process enabled operators to seamlessly switch between tasks and maintain high efficiency.

Throughout the production process, the P17A rugged panel pc collected and uploaded real-time data on workstation progress and product quality. Any deviations triggered automatic alerts, allowing operators to make immediate adjustments. Management accessed this data through the MES system to identify bottlenecks, optimize resource allocation, and resolve issues promptly. This data-driven approach significantly improved the factory's responsiveness and decision-making capabilities.

By integrating MES and ESOP with the P17A, the factory achieved a modernized production management system that enhanced efficiency, ensured product quality, and enabled agile responses to multi-model, multi-batch orders.

"With the integration of MES and ESOP systems, combined with the efficient support of ONERugged P17A Panel PCs, our workshop production management has undergone a significant digital transformation. Operational processes have become more standardized, data transparency has greatly improved, and product supply is now more stable. This is particularly evident in production transitions and quality control, helping us earn greater trust and recognition from our customers."

— Production Managerof Client's Factory

Real-time monitoring through MES and ESOP ensured every product met strict quality standards, offering customers more reliable and durable products while reducing returns and complaints.