A Cloud First MES for Fully Automated Production

A serverless industrial platform that synchronizes machines, materials and orders to create a fully digital and highly efficient factory.

ConDoor QA

𝗤𝘂𝗮𝗹𝗶𝘁𝘆
𝗖𝗮𝗽𝘁𝘂𝗿𝗲𝗱

From panel to proof. Every door. Fully documented.

Chapter 1 — The Introduction

Reinventing the Manufacturing Process with a Cloud Driven MES

ConDoor wanted a new approach to manufacturing. Instead of relying on traditional MES systems with rigid workflows and endless manual updates, they envisioned a personalized and cloud native solution that matched their unique production process. Each order at ConDoor is different, with custom dimensions, hole patterns, insulation layers and configurations. A standard MES could not provide the flexibility, automation and intelligence needed to support their factory of the future.

A platform that turns digital orders into machine ready instructions

Synadia delivered a fully serverless and event driven MES solution with seamless edge connectivity. The system receives digital orders, schedules production automatically, configures machines in real time and tracks every panel through the factory using RFID. It is specifically designed for ConDoor’s manufacturing process and is now the foundation for their new factory, with planned rollouts across additional sites in the coming years.

Chapter 2 — The challenge

Delivering a complete MES for a new factory with more than thirty machines

ConDoor asked for an ambitious solution: build an MVP in one year for a brand new factory and integrate more than thirty industrial machines into a unified digital workflow.

Automating a production process where every order is unique

Unlike mass production environments, ConDoor builds custom insulated door panels. This means every panel has different parameters: lengths, hole patterns, cutting instructions, insulation options and more. A standard MES system would require constant manual adjustments and configuration. The challenge was to design a dynamic platform that could read an order from the ERP system and automatically translate it into the correct machine instructions without human interference.

Synchronizing machines, stock and schedules across the entire production line

The new factory depends on perfect coordination between machines, stocks, transport buffers and external systems. If stock levels are not correct, if scheduling is off by minutes or if machine parameters are incorrect, the entire workflow slows down. ConDoor needed a planning system driven by more than thirty business rules that automatically determines what to produce, in which order and when. This needed to work in harmony with storage systems capable of holding more than eight hundred panels.

Creating an IIoT solution scalable enough for multiple factories

ConDoor’s goal is to expand this digital model across all factories. This required a cloud first design that could scale globally, process large volumes of events and securely communicate with industrial equipment. Machines needed to receive instructions in real time, even when multiple tasks were running in parallel. The solution had to support edge connectivity, offline resilience and millisecond level responsiveness without the complexity of traditional MES systems.

Chapter 3 — The project

A fully serverless and event driven MES with real time machine connectivity

Synadia developed a complete cloud native MES solution tailored to ConDoor’s manufacturing process, combining digital workflows, machine commands and stock movements in one integrated platform.

A dynamic production engine driven by digital orders

The MES system receives incoming orders from the ERP through APIs and immediately normalizes them into actionable production tasks. More than thirty business rules determine how each order should be scheduled, sequenced and prepared. Operators only choose which panel type to begin with. Everything else — from planning to machine configuration — runs automatically. Tasks can run in parallel or in sequence depending on production logic, all managed centrally by the MES.

Real time machine integration through cloud to edge connectivity

Every panel receives an RFID tag and registers itself at each machine. The machine then fetches the exact parameters needed for that specific panel directly from the cloud. Instructions are delivered instantly using MQTT, allowing industrial equipment to adjust cutting lengths, hole placements, speeds and other configurations automatically. The system also integrates seamlessly with the large automated storage and retrieval system that holds more than eight hundred panels, ensuring optimal flow and minimal downtime.

A scalable and future ready architecture for all ConDoor factories

The entire platform is built on a serverless event driven architecture that scales automatically with production volume. Operators and managers access a portal where roles define what each person can see or control. The solution is flexible enough to adapt to future process changes, new machines and updated workflows without redesign. It is built to become the digital backbone for all ConDoor facilities, not just the first new factory.

Chapter 4 — The result

A fully operational and highly efficient digital factory

The MES system is now running in production, delivering speed, accuracy and control far beyond expectations.

Ahead of schedule with exceptional performance

The MVP was delivered earlier than planned and immediately proved its scalability and stability. The cloud native approach enables extreme flexibility, allowing ConDoor to refine and update production logic quickly without reworking the core system. The performance and reliability exceeded expectations from day one.

Dramatically improved efficiency and waste reduction

By automating the planning process and creating a direct link between order data and machines, ConDoor has significantly reduced production waste. Saw loss and material inefficiencies have dropped, and production cycles are faster and more predictable. The combination of scheduling, stock management and real time machine instructions creates a production flow that is optimized from end to end.

Ready for rollout across all factories

The new MES platform is now the foundation for future ConDoor sites. It provides a unified way of managing production, reduces operator workload and ensures consistent output quality. With a proven architecture, the next factories can be connected significantly faster and at far lower operational cost.

Chapter 4 — The benefits

A complete digital foundation for modern manufacturing

The MES platform transforms how ConDoor manages production and sets a new standard for efficiency and automation.

Key advantages of ConDoor’s cloud driven MES

A fully automated production flow tailored to ConDoor’s unique process
Reduced waste through optimized planning and precise machine control
Real time communication between machines and the cloud
Faster production cycles with fewer manual steps
A scalable system ready for deployment across multiple factories
Strong coordination between stock, planning and execution
A task driven model that simplifies complex workflows
Lower operational cost and faster development through a serverless architecture