Intelligent Control
Control and monitor every system — WES orchestration, WCS machine control and unified SCADA visibility.
Overview
Metallum’s industrial automation software suite bridges enterprise planning with physical execution across high-throughput facilities. By integrating dynamic Warehouse Execution Systems (WES) with sub-second Warehouse Control Systems (WCS), our open-architecture platform coordinates AS/RS cranes, AGV fleets, robotic workcells, and conveyor networks in real time.
Agnostic by design, Metallum eliminates multi-vendor lock-in, optimizes order release waves, and delivers unified SCADA telemetry—maximizing system throughput and scaling continuous 24/7 fulfillment.
Types
End-to-End Workflow Optimization
Orchestrates fulfillment workflows, replenishment tasks and resource allocation — closing the gap between enterprise plans and equipment availability.
Wave & waveless fulfillment · SKU slotting · replenishment triggers
Direct Multi-Device Machine Control
Deterministic equipment driver layer managing communications with sensors, barcode readers, drives and PLCs.
PLC handshakes · fieldbus · motion coordination
Unified Dashboards
A centralized operational cockpit with live throughput KPIs, machine health, bottlenecks and alarm visualization.
Executive dashboards · maintenance consoles · multi-site
Features
Brand-agnostic middleware connects AS/RS cranes, AGVs, robotics and conveyor loops from different manufacturers.
Phased retrofits without single-vendor replacement.
Intelligent work release balances order waves, pick stations and robotic assets against live floor conditions.
Prevents workstation starvation and bottlenecks.
Low-latency control issues motion commands, diverts and tracking signals to PLCs and subsystems.
Millisecond decisions with automated fault rerouting.
Live KPIs, machine health metrics and alarm visualization in one cockpit.
Faster decisions and lower MTTR.
Pre-built connectors link SAP, Oracle, Manhattan, Blue Yonder, NetSuite and custom ERPs to automation.
Preserves your existing WMS/ERP investment.
Process
Order lines are evaluated continuously against equipment throughput, inventory locations and buffer capacity.
Totes and cases are routed dynamically to level workstation loads and prevent buffer overflow.
Equipment faults are detected instantly; detours are recalculated and tasks reassigned to parallel assets.
Compare
How the execution, control and telemetry layers divide the work.
Specification3 models | Warehouse Execution System (WES)End-to-End Workflow OptimizationRequest Demo | Warehouse Control System (WCS)Direct Multi-Device Machine ControlRequest Demo | SCADA TelemetryUnified DashboardsRequest Demo |
|---|---|---|---|
| Role | End-to-end workflow optimization | Direct multi-device machine control | Unified operational dashboards |
| Decision horizon | Seconds / sub-minute | Milliseconds / seconds | |
| Interfaces | WMS order interface, WCS dispatch queue, JSON over WebSocket, gRPC | PLC fieldbus, OPC UA, industrial Ethernet, TCP/IP sockets, OEM gateways | |
| Key functions | Wave & waveless fulfillment, SKU slotting, replenishment triggers | PLC handshakes, fieldbus, motion coordination | Executive dashboards, maintenance consoles, multi-site |
IncludedNot applicable or confirmed per project
Specifications
| Tier / layer | Classification | Decision horizon | Integration interfaces |
|---|---|---|---|
| Tier 4: ERP | Enterprise planning & system of record | Days / hours / shifts | REST API, SOAP, EDI (EDIFACT / ANSI X12), flat files |
| Tier 3: WMS | Facility inventory & operations | Hours / minutes | REST APIs, webhooks, message queues (RabbitMQ / Kafka) |
| Tier 2.5: WES | Real-time orchestration & execution | Seconds / sub-minute | WMS order interface, WCS dispatch queue, JSON over WebSocket, gRPC |
| Tier 2: WCS | Equipment routing & control | Milliseconds / seconds | PLC fieldbus, OPC UA, industrial Ethernet, TCP/IP sockets, OEM gateways |
| Tier 1/0: Machine & PLC | Field device control & sensors | Microseconds / milliseconds | EtherNet/IP, PROFINET, Modbus TCP, IO-Link, hardwired safety circuits |
| Category | Standard | Latency profile | Security & diagnostics |
|---|---|---|---|
| Industrial Ethernet & fieldbus | EtherNet/IP, PROFINET IO, Modbus TCP | Cyclic I/O; <2 ms update cycles | Media redundancy; packet-loss counters; port mirroring |
| Open middleware | OPC UA (IEC 62541), MQTT Sparkplug B | 10–50 ms | X.509 certificates; TLS 1.3; heartbeat tracking |
| Mobile robotics interface | VDA 5050 (v2.0) | 100 ms telemetry | Map sync; battery thresholds; zone speed de-rating |
| Enterprise & cloud APIs | REST / JSON, GraphQL, gRPC webhooks | Sub-second queries | OAuth 2.0 / API keys; idempotency tokens; retry queues |
Applications
Synchronize storage, sortation and shipping systems under one execution layer.
Dynamic waving and peak-season buffer smoothing.
Align material release with production schedules and robotic cells.
Connect legacy equipment and new automation without replacing everything.
Integration
WCS dispatches bin retrieval commands; the AS/RS returns crane position, status and load confirmation via OPC UA / TCP/IP with Siemens or Rockwell PLCs.
WES issues transport missions through a fleet-manager gateway using VDA 5050 over MQTT/REST.
WES passes SKU dimensions and palletizing matrices; the cell returns piece counts and finished pallet IDs.
Photo-eyes track package windows; scanners trigger lookups; WCS commands diverts in real time.
WES pushes pick instructions and SKU images; operators confirm by pick-to-light or scan-to-verify.
Profile checks, scales and dimensioners feed weight and cube to WES for freight compliance and labeling.
Resources
Automation Software
Share your facility layout, load profile and throughput targets — we will recommend the right configuration.
Products
