MES system for foam manufacturers: How to Organize Process, Data, and Production Quality

Polyurethane foam production is a highly complex process that differs significantly from standard serial manufacturing. The specificity of this industry – based on precise chemical reactions and a unique machine park architecture – requires IT solutions tailored to specific technological needs. Therefore, explitia, drawing on its experience working with companies in the automotive sector, developed a dedicated solution – the Foam MES System. It enables full digitalization and control over every stage of product creation – from chemical injection to advanced scrap cost reporting.

In this article, I show how the MES system operates in a foam factory, what data it collects from automation and ERP systems, and which functions deliver the greatest impact in everyday operations.

Let us begin with why polyurethane foam production is so unique. This process does not resemble typical serial production, where each operation follows an identical rhythm and allows for a free and straightforward flow between multiple machines.

Why is this important? A classic MES system usually focuses on managing many independent machines. In foam production, however, we deal with one enormous machine with a complex architecture (a so-called carousel), where each mold defines the parameters of a different product.

Foam is created inside a mold under the influence of temperature, and the technology somewhat resembles a “waffle maker.” Chemical agents are injected into the mold and – like waffle batter – expand to form the desired shape.

This means that:

The MES system was created to help answer the question of how your factory produces. In foam manufacturing, however, we deal with an exceptionally large number of variables. Therefore, the foundation of an MES system for foams is integration with automation (PLC, pouring robots, the line) and the recording of process data from the injection stage.

What data is collected? Among other things, information on:

This layer makes it possible to:

In practice, without this there can be no meaningful quality reports or reliable traceability.

In many foam production plants, the heart of the process is the carousel – a large machine consisting of wagons and carts, where a pouring robot injects chemicals into molds (tools).

These molds differ – depending on the intended use of the foam, we have larger elements (e.g., rear seats) and smaller parts (armrests, headrests). MES shows exactly what is happening at each position – what is being poured, what is planned, and what is being executed outside the plan.

This is important because in foam production, the “here and now” has enormous value. If the team can see on the screen:

A distinguishing feature of the explitia solution is advanced graphical visualization of production status in real time. Operators and managers do not have to rely solely on data tables. They have access to a live view that reflects the movement of the carousel on the shop floor, including the number of carousel rotations, pours, and packed units. The system informs about the status of each wagon using colors.

As a result, production employees do not have to guess anything, and the planner can see in the system whether everything is going according to plan.

In the system, you will find a reflection of individual production stages. You also have access to a range of data necessary for optimization, including:

Thanks to direct integration with PLC controllers, the system provides precise information about where each line element is located and whether the carousel is operating at the intended speed.

As in any industry, polyurethane foam production requires monitoring the OEE indicator. It includes metrics such as:

This is particularly important in foam production because the carousel may have very high efficiency, but one small issue (e.g., underfill or an excessively long cycle) immediately affects the entire throughput.

Thanks to the traceability module, every foam piece has its own unique serial number that allows you to reconstruct:

The system allows exporting this data to Excel and PDF formats for further analysis or auditing.

Effective production management on a carousel requires a flexible approach to tools. The Foam MES System offers a mold swap module that enables planning cart and mold replacements without disrupting the entire line’s workflow. As a user, you can schedule cart no. 1 to be replaced with cart no. 15, which the system records and considers in further production tracking.

Additionally, the system supports recording line availability. This makes it possible to plan technological breaks, weekends, or holidays, resulting in reliable performance calculations.

Manual stations play an important role in foam production, especially at the so-called end-of-life stage. The Foam MES System introduces an innovative scrap reporting tool. Instead of entering defect codes into a table, the operator marks the location of the defect directly on a photo of the specific product.

This data is aggregated in the form of a heatmap. If a given point on the visualization becomes intensely red, the quality department receives a signal about a recurring problem. This may suggest, for example, damage to a specific mold cavity or an issue with tool venting. Additionally, the system enables reporting component recovery – if the foam is defective but contains a metal frame, the operator can mark it as recovered, and the system sends this information to ERP, preventing incorrect booking of material losses.

An MES system for foam manufacturers is not just about automation. A crucial function of this solution is its ability to integrate with ERP software. This enables better raw material management and precise settlement of chemical consumption (in kilograms per produced unit).

In polyurethane foam production, chemical raw materials (e.g., polyol, isocyanate) represent the highest variable cost. The explitia system integrates with ERP software to collect information about:

Particularly valuable for managers is the chemical consumption report. It compares reference values resulting from the technology with actual data collected from machines. An implementation example shows that the system can detect excess consumption of 70 kg in a batch of 2,300 units, enabling quick device recalibration and avoidance of financial losses.

An important element of the system is also Quality Alerts displayed on large monitors in the production hall. The quality department can publish instructions, photos of the most common defects, or warnings regarding specific product batches.

In foam production, rejects can be difficult to diagnose. The cause of scrap may lie in:

MES supports this area with a scrapping station where the operator selects one of the available options:

The last feature is particularly powerful – the system builds a kind of defect heatmap, allowing the quality department to see where problems occur most often and link them, for example, to a tool or process setting.

Additionally, MES can consider the possibility of recovering certain components (e.g., metal elements) if they can be removed from rejects without additional cost.

In the described solution, MES also covers manual stations where, among other things, packaging takes place.

The operator packs foams into a container according to the standard (e.g., a maximum of 10 units per package), and after closing the container prints the final label, which goes to transport and ERP settlements.

This gives you control over the entire production process – from production planning and chemical distribution to packaging and shipping the final product. The final stage can be divided into several steps:

If you are considering implementing MES in a polyurethane foam production plant, pay attention to whether the system includes:

Implementing an MES system dedicated to foam production is not just an IT investment – it is primarily an optimization of a unique technological process. The flexibility of the explitia solution allows the system to be adapted to the plant’s specifics – regardless of whether production takes place on a carousel with 80 molds or stationary molds. Full graphical visualization, precise raw material cost settlement, and an innovative approach to quality control make the Foam MES System real support in daily production management. Simply put – it is the most effective way to increase profitability in the modern polyurethane industry.