MITS - Custom Manufacturing Execution Systems for High-Fidelity Process Control
Move from "Paper-to-Glass" with a flexible MES designed for the Upper Mid-Market. Real-time genealogy, error-proofing, and OEE monitoring that bridges the gap between ERP and PLC.
Bridge the gap between your ERP and your plant floor with a custom Manufacturing Execution System engineered by industrial process experts, not just software developers. Design Systems, Inc. (DSI) empowers manufacturers to eliminate operational blindness and gain absolute control over production data.
The Cost of Operational Blindness
Why "Out-of-the-Box" Software Fails Complex Processes
Many manufacturing leaders find themselves trapped by rigid, off-the-shelf MES platforms. These "black box" solutions often force you to alter your proven physical processes to fit the limitations of the software. At DSI, we reverse this dynamic. We believe software must adapt to the physical engineering reality of your plant floor. Whether you are managing complex automotive assembly or high-speed parcel logistics, a rigid software architecture eventually becomes a production bottleneck.
Signs You Have Outgrown Manual Tracking
If your facility relies on whiteboards, spreadsheets, or paper travelers to track production, you are likely hitting a ceiling in efficiency. Manual data entry introduces human error that bleeds margins and creates compliance risks.
High Scrappage Rates - You are losing material and margin due to errors that go undetected until the end of the line.
Audit Anxiety - Your team struggles to produce traceability reports for ISO or IATF audits instantly, leading to stressful, frantic preparation.
Data Latency - Your management team makes critical decisions based on yesterday’s paper travelers or Excel sheets rather than real-time data.
The "Spaghetti Code" Trap - Your Quality, Maintenance, and Production systems operate in silos and do not communicate, creating data fragmentation across the enterprise.
What is MITS (Manufacturing IT Solutions)?
MITS is the proprietary Manufacturing Execution System architecture developed by Design Systems, Inc.
MITS is a modular, brownfield-capable solution that facilitates the bi-directional exchange of data between the Enterprise Layer (ERP) and the Control Layer (PLC/SCADA).
Unlike generic software, MITS is engineered to serve as the central nervous system of your production line, providing a cohesive digital twin of your physical operations.
The Architecture of a Smart Factory (Industry 4.0)
MITS enables Industry 4.0 initiatives by transforming disparate data points into actionable intelligence. We build the architecture that allows your facility to transition from reactive troubleshooting to predictive control.
We replace physical paperwork with digital travelers and interactive work instructions displayed on HMIs and tablets.
MITS collects high-frequency time-series data from machine controllers to power advanced analytics and reporting.
We engineer secure, two-way handshakes with major enterprise systems, including SAP, Oracle, and Microsoft Dynamics, ensuring your top floor knows exactly what is happening on the shop floor.
MITS Functional Capabilities
Traceability and Genealogy (The "Birth Certificate" of the Part)
For Tier 1 automotive suppliers and MedTech manufacturers, traceability is not optional; it is a mandate.
MITS generates a complete digital "birth certificate" for every unit produced. The system tracks raw goods from the moment they enter receiving to the finished product.
This includes batch tracking, lot control, and precise serial number association. In the event of a recall, you can isolate affected units in seconds rather than days, protecting your OEM contracts and your reputation.
Error Proofing and Quality Control (Poka-Yoke)
We integrate MITS directly with physical hardware to prevent errors before they occur.
By interfacing with Pick-to-Light systems, torque controllers, and vision systems, MITS physically prevents a part from moving to the next station if a step is missed or a tolerance is not met. This ensures that only 100% conforming parts reach the end of the line.
Order Management and Scheduling
MITS seamlessly pulls production schedules from your ERP and manages the queue at the line side. This capability is critical for facilities managing high-mix, low-volume production or complex build variants.
The system ensures the right components are available for the specific model being assembled, eliminating confusion for operators.
Maintenance and Andon Management
Reduce downtime with predictive maintenance alerts and real-time Andon visualization.
MITS monitors machine health and displays status across the facility.
When a line stops, the system identifies exactly why Line 3 is down and alerts the appropriate support team immediately, drastically reducing Mean Time to Repair (MTTR).
Lean Manufacturing Integration
We use MITS to digitally implement proven Lean methodologies. The system supports Value Stream Mapping (VSM), automated Kanban loops, and Just-in-Time (JIT) material flow.
This digital enforcement of Lean principles ensures that your process remains efficient and standardized across all shifts.
Why Design Systems, Inc? The Engineering Advantage
We Fix the Process, Not Just the Code
Most MES providers are pure software vendors.
They may write clean code, but they rarely understand conveyor physics, laser scanning, or industrial engineering.
If a sensor is blocked by a guardrail, a software vendor cannot fix it.
Design Systems, Inc. can.
We approach MES as engineers first. We analyze the physical constraints of your line,from ergonomics to cycle times, and build software that enhances the process rather than complicating it.
Seamless "Paper-to-Glass" Transition
We specialize in "Brownfield" integration. We understand the complexity of migrating legacy facilities to digital environments.
Our team has decades of experience deploying systems in active plants without disrupting current production quotas. We ensure a smooth, low-risk transition from manual paper tracking to digital visibility.