Leading Edge MES Software.
Integration Makes the Difference.  

There are many companies that “sell MES software”, but at Nysus Solutions, our dedication to a successful integration is what sets us apart. We have a highly qualified team of manufacturing professionals who will work with your team to ensure that your manufacturing execution system installation is a success.

With the ability to easily customize the system to fit your exact requirements, you can be sure the Nysus Solutions Manufacturing Execution System will become an indispensable part of your manufacturing organization.

Nysus Solutions MES provides a common user interface across all systems and can be customized to fit specific user requirements like text language and images.

What an MES Actually Does on Your Shop Floor

A Manufacturing Execution System is the operating layer between your ERP and the equipment, operators, and devices on the production floor. The ERP tells you what to build and when. The MES makes sure it actually happens correctly — and captures the evidence that it did.

The Nysus Solutions MES handles the work that lives in the gap most ERPs leave wide open: real-time work-in-process (WIP) tracking, BOM-driven operator guidance, station-by-station verification, PLC and tool integration, defect collection, and per-unit traceability. The result is a closed-loop shop floor where every build step is guided, every result is captured, and every unit is fully accountable from raw material to shipped product.

Unlike alternative MES platforms that force your process to conform to their data model, the Nysus MES is built on a foundation we customize to match your products, your stations, and your operators — without sacrificing the upgrade path or long-term supportability.

Architecture & Technology

The Nysus MES is a modern, web-based platform built on industry-standard technologies — designed to scale from a single station to a multi-plant deployment without changing the underlying architecture.

Web-Based Client — Browser-based operator and supervisor interfaces — nothing to install on station PCs. Touchscreen-friendly with responsive layouts that work on station-mounted panels, ruggedized tablets, and supervisor desktops alike.

Industry-Standard Database — Microsoft SQL Server or PostgreSQL back-end with full backup, replication, and disaster recovery support. Your data stays in your control, in your data center or your cloud — never locked into a proprietary cloud-only platform.

On-Premise, Private Cloud, or Hybrid — Deploy on your own servers, in a private cloud, or as a hybrid — your choice. Critical real-time station functions can run locally for resilience while reporting and analytics run centrally.

Real-Time PLC Connectivity — Direct PLC communication via native drivers for Allen-Bradley (Logix, ControlLogix, CompactLogix, MicroLogix), Siemens (S7-300/400/1200/1500), FANUC, Omron, GE, ADAM, and Modbus TCP/RTU. No middleware OPC server required for most platforms.

Open Protocol Torque Tool Integration — Native Open Protocol over Ethernet with all major tool platforms — Atlas Copco, Bosch Rexroth, Ingersoll Rand, Apex (Cleco), Desoutter, Stanley. Automatic PSET selection driven by the unit's BOM, with per-fastener traceability.

Vision System Integration — Direct integration with Keyence, Cognex, FANUC iRVision, and other major platforms — capturing pass/fail, image evidence, measurements, and metadata against each unit serial.

Configurable Without Custom Code — Work instructions, station logic, BOM rules, defect codes, and reports are configured through admin tools — not coded. New product launches and engineering changes do not require a software release.

REST and SOAP Web Services — Standards-based APIs for ERP, WMS, CMMS, quality, and analytics integration. Bidirectional data exchange with all major ERP platforms.

Active Directory / SSO Support — Operator and supervisor authentication via your existing AD or LDAP infrastructure, with role-based access control and full audit trail.

Multi-Language & Multi-Site Ready — Operator interfaces support full localization (text, images, units of measure). Multi-plant deployments share a common code base with site-specific configuration.

Why Choose Nysus Solutions

There are dozens of companies that sell MES software. There are very few that actually deliver one that runs reliably in production for years. The difference is rarely the software itself — it is the team behind it and the integration discipline they bring to the project.

Nysus Solutions has been building, deploying, and supporting MES installations across automotive, lawn & garden, heavy equipment, appliances, and industrial products. Our engineers do not just implement screens; they understand PLC programming, torque tool protocols, vision systems, robotics, and ERP integration — because we build the automation systems those technologies live in.

When you choose Nysus, you are not choosing a software publisher with a network of resellers. You are choosing the team that will be on your floor, on your network, and on the phone at 2 AM if your line goes down.

Our Differentiators

One Team, Whole Solution — MES, WMS, CMMS, ERP integration, and automation can all delivered by the same company. No finger-pointing between integrators.

Manufacturing-First Engineering — Our engineers come from manufacturing — many have run production lines themselves. We design for the shop floor, not the marketing demo.

True Customization Without Lock-In — Customize the system to match your process without forking the codebase. You keep the upgrade path; you keep flexibility.

Native PLC & Tool Knowledge — We program PLCs and integrate tools every day. The MES connectivity layer is built by the people who understand both sides of the wire.

24/7 Support from People Who Built It — Direct access to the engineers who built your system. Not a tier-1 call center reading from a script.

Built to Integrate with Everything Else You Own — PLCs, torque tools, vision systems, ERP, robotics — we work with what you already have rather than forcing rip-and-replace.

FEATURES

  • Factory assembly line with workers and machinery following MES instructions

    Automated Work Instructions

    Provide step by step guidance for each specific bill of material (BOM).

  • Close-up of a ControlLogix chassis with multiple modules and connected cables.

    PLC Integration

    Directly connect shop floor PLCs including Allen Bradley, ADAM, GE, FANUC, Siemens, Omran, and ModBus.

  • Automated assembly line with a robotic screwdriver, metal structures, wires, yellow components, and a warning label in a manufacturing facility.

    Torque Tool Integration

    Instantly connect to torque controllers and trigger PSETs via open protocol.

  • Barcode with laser scanning line and numbers.

    Product Traceability

    Capture all manufacturing information including operators, bar codes, PLC outputs, test results, and images.

  • Person holding a barcode scanner near an industrial machine using MES in a factory setting.

    Barcode Verification

    Ensure proper component selection and finished product traceability.

  • Statistical process control charts with data points, control limits, and trend lines showing monitoring analysis outcomes.

    Process Parameter Monitoring

    Detect process issues and prevent defective products.

  • Keyence vision sensor with LED lights

    Vision System Integration

    Identify defects inlcuding missing components, incorrect options, color and tolerance.

  • White automotive panels in a workshop setting with markings and grids for measurement or quality control.

    Defect Collection

    Utilize scatter plots to identify defect types and locations.

  • industrial workstation with MES computer monitor and assembly tools

    Projected Work Instructions

    Highlight assembly steps directly on product surface.

  • Screenshot of a software interface with a "Create Help Request" menu displaying options for "Materials," "Maintenance," "Quality," and "Process Tech," each with associated barcodes. A "Cancel" option with a yellow barcode is at the bottom. The background shows sections titled "Scan Badge Operator" and "Operator Timer." The interface displays time, date, and other operational details.

    Call For Help

    Properly support operators with automated calls to maintenance, quality, IT, and safety.

  • O2COOL safety alert screen with pinch point warning, showing a photograph of a manufacturing line area marked with a red box highlighting a potential pinch point beneath assembly trays.

    Training Verification

    Verify operator qualifications and training prior to station log-in.

  • A screen displaying rack loading status with serial numbers. It shows many green boxes labeled 'LOADED TO RACK,' a yellow box labeled 'SCANNED VERIFY SERIAL,' and several boxes marked 'IN-QUEUE' and 'IN-BUILD.' There are buttons at the bottom labeled 'LOGOUT,' 'HELP REQUEST,' and 'CLOSE.'

    Pack Out

    Guarantee proper quantity, content, and sequence of final containers.

  • Screenshot of a shipment loading dashboard for shipment number 1076690. It shows rack IDs, positions, and statuses. Some racks are marked 'Loaded to Truck' with green highlighting, while others are 'Staged' with yellow highlighting. Instructions to scan rack 615657 are also displayed.

    Shipping

    Certify proper truck loading through bar code scanning or RFID integration.

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Industries & Use Cases

Automotive Tier 1 & Tier 2 — Sequenced delivery, OEM broadcast integration, torque traceability, and full unit genealogy for IATF 16949 quality systems.

Lawn & Garden / Outdoor Power Equipment — Mower, ATV, and small engine final assembly lines — including option-level verification, build-to-order, and end-of-line testing.

Heavy Equipment & Off-Highway — Large-frame, long-cycle build operations with multi-station fixturing and full assembly traceability.

Appliances & White Goods — High-volume mixed-model assembly with cosmetic inspection, leak testing, and functional verification.

Industrial Products — Pumps, motors, gearboxes, valves — engineered-to-order assembly with per-unit performance records.

Medical Devices — Regulated assembly with electronic device history records and full per-unit traceability.

Modular Homes — High option content, large station areas, quality and fit and finish auditing.

Deployment & Integration

Free On-Site Evaluation — Every project starts with an on-site walk of your operation, your current systems, and your goals — at no cost.

Phased Implementation — Start with one line or one station; scale as the value is proven. No rip-and-replace required.

Existing-System Integration — Connect to your existing ERP, WMS, CMMS, quality, and analytics systems via REST, SOAP, file-based interfaces, or direct database access.

Operator & Maintenance Training — On-site training for operators, technicians, IT, and supervisors. Train-the-trainer programs available for large rollouts.

24/7 Production Support — Around-the-clock support through our customer support team. Critical-system issues get an engineer on the line, not a triage agent.

Ongoing Continuous Improvement — The MES grows with your business. Adding new lines, stations, and products is a configuration exercise, not a re-implementation.

Unlock Your Manufacturing Efficiency!

Contact us today to get started

sales@nysus.com
(877) 830-8624

403 Tomahawk Drive
Maumee, Ohio 43537