Zestfloor Connective MES
for Smarter Industries

Enhancing Manufacturing Efficiency Through Real-Time Visibility & Seamless Connectivity​

An advanced and intelligent Manufacturing Execution System (MES) designed to bridge the gap between Operational Technology (OT) and Information Technology (IT). The platform seamlessly connects machines, production lines, and enterprise systems to deliver real-time visibility, automation, and operational intelligence across the shop floor.

Powered by Industrial IoT (IIoT) and machine learning technologies, Zestfloor enables intelligent manufacturing operations through real-time machine connectivity, production monitoring, and data-driven decision-making.

By transforming the shop floor into a connected and automated manufacturing environment, Zestfloor improves agility, productivity, traceability, and operational efficiency.

Zestfloor also enables the creation of a digital twin — a virtual representation of the manufacturing facility — allowing organizations to monitor current and historical production states, optimize processes, and drive continuous improvement initiatives.


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Zestfloor - A Manufacturing Solution Supporting the 'Physical–Digital–Physical' Loop

Zestfloor enables a seamless integration between shopfloor operations and digital intelligence — creating a continuous loop where physical processes generate data, digital systems analyze it, and insights drive optimized physical actions.

From Data Acquisition to Process Streamlining

A smart factory ecosystem powered by connected machines, sensors, and advanced analytics transforms raw production data into actionable insights.

With real-time visibility and control tower capabilities, manufacturers can improve resource utilization, enhance productivity, and ensure consistent quality across operations.

Bridging Physical Operations and Digital Intelligence

Digitalize the Data Entry  right from Material in to the respective Storage Location at each Plant. Followed by the planning to be carried out for Resourcing, Production and Capacity.

Capacity Planning
Production Planning
Resource Planning

Automated data capture connects directly with machines and equipment or integrates through system-generated data feeds. This enables:

  • Real-time monitoring of production parameters
  • Advanced analytics and reporting (CP, CPK, PP, PPK)
  • Faster identification of process variations and improvements
  • Data-driven decision-making across the shopfloor

Quality Assurance Before despatch

Post-production, all products and accessories undergo physical quality checks before being moved to the Finished Goods (FG) warehouse. This ensures that only compliant, high-quality products proceed to despatch—reducing rework and customer complaints

Zestfloor – Business Architecture

PLAN

Production Planning

Production order, BOM, Routings, Variants, Operations, Work center, Shift Roster, Work Centre Groups.

Inventory Management

Material classification, Inventory, Reservations, Stock, Storage locations, Goods Receipt, etc.

Quality Management

Inspection lots, characteristics / attributes, Non conformance, etc.

Version Management

BOM, Recipe Changes to be captured with version effectivity

EXECUTE

Production/ Job Order

Job Card

Monitoring/ Data Capturing

Test & Re-work

Packing & despatch

Yield confirmation, Scrap confirmation, Rework confirmation, Goods movements, Material consumption, Resource Time booking, Quality inspection results,, Equipment usage, Tool usage.

AUTOMATION

Plant DB

Wireless Integration

Mobile Compatible

Sensors

SCADA/HMI

Automation to capture the movements, identify the Problem areas and Track the flow in Shop Floor. Paperless Solutions towards real time capturing of data.

Traceability   Interoperability    Real-Time   Control

Zestfloor EMS empowers manufacturers with real-time quality monitoring through seamless interoperability across machines, systems, and processes.


By integrating with iBWMS, Zestlink, and Turbozest, Zestfloor delivers a fully connected data ecosystem providing end-to-end visibility from

Zestfloor smart manufacturing
Material Inward → SMT → Assembly → Packaging → despatch
Faster
Connectivity.
Smarter
Operations.

With our proprietary communication protocol, any machine—regardless of make or model—can be integrated into your ecosystem within days, not months.


This eliminates traditional integration challenges and accelerates digital transformation.

End-to-End
Traceability

Track and monitor every element across your manufacturing lifecycle with complete digital traceability at each stage.

  • Process Traceability
  • Product Traceability
  • Component Traceability
  • Consumables Tracking
  • Tool Traceability
Real-Time
Intelligence
Across the
Shopfloor

  • Enable Machine-to-Machine (M2M) & Machine-to-Human (M2H) communication

  • Get instant alerts and actionable insights during production

  • Ensure complete visibility for all connected stakeholders

Zestfloor – Enabling the Digital World

OCR

OCR enablement supports and makes life easier where the majority of companies have challenges since none of ERPs or any application captures critical data like MPN, Mfg. date and LOT number. It also saves $$ by avoid buying Machines.

Interlock

Interlocking at every possible stage right from SMT to Assembly eliminating the possibility of defect boards to move down the line. Use of PLC automation to STOP the conveyor in case of anomaly either in materials, machines or processes.

Traceability

Complete automation of traceability end to end including WIP tracking and Handling nit where the SMT or boards that are completed with processes are stocked.

Process and Part traceability Automation.

Machine Data

Ability to integrate all Model and Make of Machines in SMT, Assembly and Testing Lines. We also provide the option of having all done in our application saving you the cost of licenses but still provide all the features expected.

Customer Success