Factory Simulation
Machines, data model, MCP domains
Overview
The OpenShopFloor factory simulation models a complete manufacturing facility with CNC machining, injection molding, assembly, and quality control. The simulation runs continuously, generating realistic production events, machine state changes, quality data, and order progress.
All data is stored in PostgreSQL databases and exposed through MCP tools. You can view the live factory state on the Factory Dashboard.
Production Areas
CNC Machining
5 CNC turning and milling centers (CNC-01 to CNC-05). Each machine processes metal parts with individual cycle times, tool wear tracking, and maintenance schedules. Machine states include running, idle, setup, maintenance, and stopped.
Injection Molding (SGM)
3 injection molding machines (SGM-01 to SGM-03) producing plastic components. Each machine tracks cycle times, shot counts, mold temperature, and material usage. Quality data includes short shots, flash, sink marks, and dimensional checks.
Pre-Assembly
Sub-assembly operations that combine CNC and SGM parts into intermediate assemblies. Tracks station utilization, assembly sequence, and component availability.
Final Assembly
Multi-station assembly line for finished products. Each station has individual cycle times and quality checks. Station-level tracking shows throughput and bottlenecks.
Test Field
End-of-line testing with functional checks and quality verification. Pass/fail data feeds into the QMS for defect tracking and root cause analysis.
Key Metrics
OEE (Overall Equipment Effectiveness)
Calculated per machine as Availability x Performance x Quality. World-class target is 85%. Available per machine and as factory average via factory_get_latest_oee.
On-Time Delivery (OTD)
Percentage of customer orders delivered on or before the promised date. Tracked per customer and overall via factory_get_customer_otd.
Defect Rate
Parts per million (PPM) defective, tracked per machine and product. Defect types include dimensional, visual, and functional defects.
Capacity Utilization
How much of the available capacity is being used. Shown per machine, per area, and factory-wide.
Data Model
The simulation uses several interconnected data domains:
- Machines — ID, type, area, status, current order, cycle time, OEE components
- Production Orders — Order ID, product, quantity, due date, priority, status, routing steps
- Materials — Stock levels, reservations, reorder points, lead times
- Quality Records — Inspection results, defect types, SPC data, CAPA actions
- Tools — Tool inventory, wear levels, expected life, replacement schedule
- Customers — Customer data, delivery history, OTD performance
MCP Integration
Each data domain is served by a dedicated MCP server. The gateway proxies tool calls to the right server based on the tool name prefix:
| Prefix | Server | Domain |
|---|---|---|
| factory_ / tms_ / sgm_ / montage_ | factory-sim:8020 | ERP, OEE, capacity, MRP, maintenance, energy, stock, TMS, SGM, assembly |
| uns_ | mqtt-uns:8025 | Live MQTT machine data, topics, alerts |
| kg_ | kg-server:8035 | Knowledge Graph, semantic search, charts |
| history_ | historian:8030 | Time-series trends, anomalies |