Your MES Should Run Your Floor.
Not the other way around.
Proficy Plant Applications is one of the world’s most powerful MES platforms — covering OEE, quality, production tracking, batch analysis, and genealogy. Rain Engineering makes it actually work for your plant.
with MES (LNS Research)
Plant Apps development
Why Most MES Implementations Fall Short
Proficy Plant Applications is a powerful platform. But like any enterprise system, the software is only as effective as its configuration, integration, and adoption. These are the gaps Rain Engineering closes.
Data collected, never used
Teams configure tags and start collecting data — but without the right model structure, the data sits in the database and no one can answer basic questions like “why did Line 3 drop OEE last Tuesday?”
ERP stays disconnected
Production orders live in SAP or Dynamics. Quality results live in Plant Apps. They never talk. Operators work from two screens and reconcile manually — which is exactly what MES is supposed to eliminate.
OEE tracking without context
The Efficiency module tracks downtime — but without a proper downtime reason code hierarchy, all the reports say “Other”. You can see that something went wrong, but not what or why.
Quality data entered but not enforced
The Quality module is configured for data entry, but limits and specs weren’t tied to each product version. A quality deviation gets logged after the fact instead of flagged in real time.
Genealogy missing the detail that matters
A recall notification arrives. The genealogy tree shows the batch number but not which specific components, sub-assemblies, or operators were involved. The investigation takes weeks instead of hours.
System goes live, team goes dark
The implementation partner deploys, closes the ticket, and moves on. Six months later, the team can’t add a new product, modify a quality form, or explain to a new hire how the system works.
Everything Your Plant Needs in One MES Platform
Proficy Plant Applications is built around four powerful modules — each solving a distinct production problem. Rain Engineering configures, integrates, and maintains all four.
Efficiency Management
Tracks and monitors Overall Equipment Effectiveness (OEE) and other critical KPIs — including downtime, waste, production counts, MTBF, and MTTR. Gives supervisors a real-time view of line performance and root cause analysis tools to act on what they see.
- Real-time OEE tracking by line, shift, and product
- Downtime reason code hierarchy — no more “Other”
- Waste and scrap tracking with causal analysis
- MTBF / MTTR reporting for maintenance planning
- Automated alerts on threshold breaches
Quality Management
Provides quality data entry, real-time limit checking, and tracking tied to each specific product and specification. When a result is out of spec, the system flags it immediately — not after the batch ships. Supports statistical process control (SPC) and non-conformance management.
- Product-specific quality specs and limits
- Real-time SPC and out-of-control alerts
- Non-conformance (NCR) creation and routing
- Mobile-friendly quality entry on tablets
- Certificate of Analysis (COA) generation
Batch Analysis
Purpose-built for process manufacturers running batch and campaign production. Captures all process variables, compares batch performance against the golden batch, and supports FDA 21 CFR Part 11 compliance. Integrates with Historian for full process data context.
- Golden batch comparison and deviation tracking
- FDA 21 CFR Part 11 and EU Annex 11 ready
- Batch record creation and electronic signatures
- Phase-by-phase process variable capture
- Integration with Proficy Historian for full time-series context
Production Management & Genealogy
Manages production orders, tracks work-in-process (WIP) in real time, and builds a complete genealogy tree for every unit and batch. Supports discrete, process, and mixed manufacturing environments — and connects to ERP for bi-directional order management.
- Full bill of materials (BOM) and genealogy tracking
- WIP visibility across all work centers
- Bi-directional ERP integration (SAP, Dynamics, Oracle)
- Browser-based operator work instructions
- Route management and order sequencing
What Changes When You Work with a Specialist Partner
Most MES implementations stall not because the software doesn’t work — but because configuration decisions made at go-live create problems that compound for years. These are the decisions Rain Engineering gets right from day one.
| Area | Without Rain Engineering | With Rain Engineering |
|---|---|---|
| OEE Model Design | Default equipment hierarchy copied from specs. Downtime reasons don’t match how operators actually work. Reports are noise. | Equipment hierarchy and reason code taxonomy built around your actual production model. OEE data is immediately actionable. |
| Quality Spec Setup | A generic spec template applied to all products. Out-of-limit events are logged but not routed. Quality team still chases paper. | Spec limits configured per product version. Out-of-limit events trigger automatic NCR creation and notify the right people instantly. |
| ERP Integration | ERP stays disconnected. Operators manually enter order info into MES. Reconciliation takes hours every day. | Bi-directional ERP integration — orders flow in, actuals flow back. Rain Engineering handles all 20+ out-of-the-box message types and custom mappings. |
| Shop Floor Connectivity | Manual data entry or basic OPC tags. Many devices never connected. Production data arrives late or not at all. | Full device connectivity via Proficy IGS or Kepware — PLCs, CNCs, robots, vision systems. Rain Engineering specializes in shop floor connectivity. |
| Batch Analysis | Batch records created but golden batch never defined. Deviations aren’t compared to anything. Compliance risk. | Golden batch defined for each product family. Deviation alerts configured. Electronic batch records reviewed and signed off in the system. |
| Genealogy Depth | Top-level batch tracked but sub-assembly and component genealogy missing. Recall investigations still take weeks. | Full BOM genealogy from raw material receipt to ship — every component, every operator, every step. Recall response time: hours, not weeks. |
| Long-Term Support | Go-live, close ticket, move on. Team can’t maintain the system, add products, or troubleshoot independently. System stagnates. | 2 hour support SLA. Dedicated education programs. System evolves as your plant evolves. Rain Engineering is a long-term partner, not a one-time deployer. |
Rain: The Authority on Proficy Plant Applications
Implementation is just the beginning. Rain Engineering brings the deep product knowledge, shop floor fluency, and long-term commitment to make your MES investment return value for years.
Velotic Proficy Platinum SI Partner
The highest certification tier for Proficy solution providers. Rain Engineering has earned it across every Proficy product — including all four Plant Applications modules — not just one specialty area.
Shop Floor Connectivity Specialists
Proficy Plant Applications is only as good as the data it receives. Rain Engineering connects your PLCs, CNCs, robots, and vision systems directly to MES via IGS and Kepware — so data is real and current, not estimated or entered manually.
Configuration Before Go-Live
The decisions that make or break a MES — OEE model design, downtime reason taxonomy, quality spec architecture, ERP message mapping — happen before go-live. Rain Engineering gets these right the first time.
Education Embedded in Every Project
Every Rain Engineering engagement includes structured knowledge transfer. Your team learns how to maintain the system, add new products, and troubleshoot independently — so you don’t need to call us for every change.
2 Hour Support Response
When your MES goes down or a quality alert fires at 2 AM, a 72 hour ticket is not acceptable. Rain Engineering’s support SLA guarantees a response within two hours — because production doesn’t wait for business hours.
Long-Term Manufacturing Partner
Most SI partners optimize for deployment speed. Rain Engineering optimizes for long-term value. We stay engaged as your plant evolves — adding lines, new products, new integrations — and make sure the system grows with you.
The People Who Feel MES Pain The Most
Proficy Plant Applications serves multiple roles across the plant floor. Rain Engineering designs implementations that deliver clear wins for each one.
The Data Architect
I can get data from the line into Historian. But making it meaningful in Plant Apps — the right OEE model, the right quality specs — that’s where I need a partner who’s done it before.
The Decision Maker
I need to know why OEE dropped on Line 3 last Tuesday — not next Friday when someone runs a report. And I need the quality team to catch problems before they become holds, not after.
The Record Keeper
A recall request comes in. I need to trace every component in that batch back to its raw material lot in minutes. If the genealogy isn’t built right, we’re spending weeks on investigation instead of hours.
What Rain Engineering does with Plant Applications
From new implementations to system rescues to long-term optimization — Rain Engineering provides the full lifecycle of MES services.
New Implementation
Full-scope deployment of one or more Plant Applications modules — from requirements and OEE model design through go-live, training, and first-value milestone in Week 2.
System Assessment & Rescue
If your Plant Applications system was deployed but never delivered the expected value, Rain Engineering audits what was built, identifies root causes, and restructures it to perform.
ERP & Device Integration
Bi-directional integration with SAP, Oracle, Dynamics, and other ERP systems. Direct device connectivity from PLCs, CNCs, robots, and sensors via Proficy IGS or Kepware.
Module Expansion
Already running Efficiency? Add Quality, Batch Analysis, or Genealogy — with the architectural consistency to make all four modules share data and context seamlessly.
Training & Education
Role-based training for operators, supervisors, quality technicians, and administrators. Workshop formats available. Delivered on-site or remotely, scheduled around your production calendar.
Ongoing Support & Optimization
2 hour response SLA. Proactive system monitoring. Regular optimization reviews to extend value as your plant adds products, lines, and complexity.
AtriCure went from Excel chaos to real-time production control
“Rain Engineering specializes in the use and support of manufacturing systems — what you have in place today, and what you’re thinking about implementing tomorrow. Their tools and services streamline systems change and help you make the most of your technology investment. Results were better than anticipated.”
— Chuck Kirkendall, Sr. Manager, Demand Planning & Inventory Management at AtriCure
Ready to get real value from Proficy Plant Applications?
Whether you’re starting fresh, rescuing a struggling implementation, or expanding to new modules — Rain Engineering has done it before and can do it for you.
FAQs
Proficy Plant Applications is Velotic’s MES platform for managing OEE, quality, batch analysis, and production genealogy across your plant. It connects machines, operators, and business systems so you can see what is happening in real time and act on it.
Plant Applications helps reduce unplanned downtime, catch quality issues earlier, and shorten recall investigations from weeks to hours. It replaces manual reconciliation between ERP, quality systems, and shop floor data with one connected MES model.
Plant Applications includes four core modules: Efficiency (OEE and downtime), Quality, Batch Analysis, and Production/Tracking & Genealogy. Each module targets a specific production problem but works together as one system when implemented correctly.
Yes. Rain Engineering delivers bi-directional integration with ERP systems like SAP, Oracle, and Dynamics so orders flow into MES and actuals flow back. We also connect PLCs, CNCs, robots, and vision systems through Proficy IGS and Kepware so MES sees real production data, not manual estimates.
Rain Engineering focuses on model design, quality spec architecture, ERP message mapping, and device connectivity so the data in Plant Applications is accurate and actionable. We also provide training and support so your team can maintain and extend the system instead of relying on one-time deployers.
Rain Engineering offers a 2-hour response SLA, proactive monitoring, and regular optimization reviews for Plant Applications. Role-based training for operators, supervisors, quality, and admins helps your team use the system confidently and keep improving it over time.