With version 11.2, Critical Manufacturing MES brings powerful support for negative BOM item quantities, enabling real tracking of by-products generated alongside main products.

This innovation answers real user requests and opens the door to smarter, ecologically aware production management. Let’s explore what this feature means, the problems it solves, and how it helps turn production “waste” into value.

The Challenge: Tracking By-Products in Manufacturing

In many manufacturing processes, producing a final product also creates by-products or leftovers that must be accounted for. Simple examples include:

• Juice production generating fruit peels usable for essential oils or bio-fuels.
• Metalworking creating scrap material that can be recycled.
• Food processing yielding waste products possible as feed or compost.

It is common for systems to be focused only on components consumed during assembly, making it difficult to record by-products as part of the production flow.

This gap caused:

• Lack of traceability for valuable leftovers or secondary materials.
• Difficulty integrating by-products in inventory and reporting.
• Missed opportunities to repurpose or recycle materials efficiently.

What’s New in 11.2: Negative BOM Item Quantities

Critical Manufacturing 11.2 introduces native support for negative quantity BOM items, allowing by-products to be defined and tracked directly within the BOM. Here’s what that entails:

• By-products are BOM items with negative quantities, configurable only under Materials scope.

  

• Consumption happens in reverse: Instead of reducing inventory, assembly increases the quantity of by-products.

• Substitutes are not allowed for negative items, ensuring clear material tracking.

Practical Benefits

• Integrates by-product tracking seamlessly into BOM-driven assembly/disassembly.
• Provides full visibility and traceability of all materials flowing through production.
• Simplifies setup by avoiding the need for separate “waste” processes or manual inventory adjustments.
• Enhances data quality for cost control, reporting, and sustainability initiatives.

Final Thoughts

Handling by-products efficiently is vital for modern manufacturing - both for operational accuracy and environmental stewardship. Critical Manufacturing MES 11.2’s negative quantity BOM items empower companies to track, manage, and repurpose leftovers.

By embracing this feature, manufacturers align with sustainability goals while gaining operational clarity. It’s another step toward smarter, greener production that benefits the business and the planet. 🌱

For more details and configuration tips, explore our full BOM Tutorial series and User Guide.

Author

Hi! My name is Sofia Rodrigues. ☺️

I joined the Critical Manufacturing family back in the striking year of 2020 as an MES Consultant/Functional Analyst. In 2023, I transitioned to the Product Documentation team, where I now focus on designing and creating content.

You can check me on LinkedIn

Skills: Functional Analysis | System Testing | User Training | Technical Writer

How do you achieve that without compromising traceability, efficiency, or shop floor clarity?

Critical Manufacturing MES 11.2 introduces this capability with Mixed Assembly. This feature allows multiple BOM assembly types to coexist seamlessly within the same production step.

Let’s dive into what Mixed Assembly means, the challenges it solves, and how it unlocks new operational flexibility.

The Challenge: Diverse Assembly Needs in One Step

Typical BOM consumption behavior in MES systems has historically been fixed at a contextual level, all items in a BOM consumed the same way per step. But manufacturing reality is - if you allow me - messier:

• Some components need manual tracking and explicit assembly to ensure quality or customization.
• Others suit an automated assembly triggered at material track-in or track-out events for speed and reliability.
• Attempts to blend these had complex workarounds: splitting steps, reconfiguring BOM contexts, customizations, or compromising traceability.

Introducing Mixed Assembly: The Best of Both Worlds

In version 11.2, the Mixed Assembly feature shifts control from BOM context to the BOM Item level, enabling different assembly type side-by-side within the same production step.

How it Works

• At the BOM level, enable the “Assembled Mix Mode” and define a base explicit assembly type: Explicit, Explicit Add, or Explicit Long Running, and this behavior is fixed per BOM and cannot vary per context.

  

• At the BOM item level, override the manual behavior for selected components by specifying automatic consumption behaviors: Automatic at Track-In or Automatic at Track-Out.

  

• In the BOMContext Smart Table, set the Assembly Type to Mixed.

  

• Available only for BOM Scope is set to Material.

• Components flagged for automatic assembly consume themselves during standard material events, while others require manual operator assembly.

Real-World Benefits

⚡ Enhanced Flexibility

Manufacturers can now:

• Mix delicate, manually assembled parts with automated consumables on a single line.
• Avoid splitting production steps unnecessarily, simplifying flow and operator training.

🚀 Optimized Efficiency

• Automated consumables (like adhesives or fasteners) reduce manual errors and speed up throughput.
• Manual assembly items maintain the needed control for quality and customization.

🔖 Improved Traceability

• All assembly actions remain fully recorded and traceable, regardless of consumption mode.
• BOM item-level assembly types offer granular insights into exactly how components were consumed.

Example Use Case

Imagine a production step where:

• Product A requires manual assembly of a customer-specific BOM Item Module, to be assembled with Explicit assembly type.
• Meanwhile, BOM Items like screws and labels are automatically assembled at Track-Out.

The BOM would have to be configured to have the Assembled Mix Mode set to Explicit, and the BOM Item Module would inherit this assembly type. When configuring the BOM Items screws and labels, the Assembly Type needs to be Automatic at Track-out.

When configuring the BOM Context Smart Table, the system will automatically assume the Assembly Type as Mixed. The BOM should be configured with the Assembled Mix Mode set to Explicit, so that the BOM Item Module inherits this assembly type. For BOM items such as screws and labels, set their Assembly Type to Automatic at Track-out. When configuring the BOM Context Smart Table, the system will automatically recognize the Assembly Type as Mixed.

This way, Mixed Assembly enables this blend effortlessly, matching shop floor needs without complicated workarounds.

Final Thoughts

Mixed Assembly feature in Critical Manufacturing MES 11.2 is a game changer — joining flexibility, efficiency, and traceability on the factory floor. It addresses the diverse assembly needs within unified production steps, reflecting the true complexity of modern manufacturing.

Consult our detailed BOM Tutorial and User Guide to configure and roll out Mixed Assembly smoothly.

Author

Hi! My name is Sofia Rodrigues. ☺️

I joined the Critical Manufacturing family back in the striking year of 2020 as an MES Consultant/Functional Analyst. In 2023, I transitioned to the Product Documentation team, where I now focus on designing and creating content.

You can check me on LinkedIn

Skills: Functional Analysis | System Testing | User Training | Technical Writer

In version 11.2, Critical Manufacturing MES raises the bar for BOM flexibility. Fixed consumption, tolerance ranges, information capture and assembly ad-hoc operations - these features solve longstanding challenges for every manufacturing engineer who has faced a process that refuses to fit a strict mold.

This post explores new capabilities, why it matters, and how it solves everyday problems on the shop floor.

Fixed Quantity BOM Items

What is the real challenge?

Most BOMs scale linearly: 10 products require 10 times the parts. But some processes break this rule. Think of disinfectants for sanitizing a line - whether you are assembling 1 or 1,000 units, only one bottle is used for the whole batch. The same is true for quality test kits or glue packs included per order, not per unit.

With 11.2, fixed quantity BOM Items enhancement, we enable direct configuration of BOM Items with a fixed quantity, regardless of batch size. Set it, and production reporting reflects reality.

This feature addresses concerns such as:

• Inaccurate material planning for fixed-use items
• Over-consumption and waste when “per unit” logic is reused by force
• Workflow rigidity for items needed just once per order

Setting up Fixed Quantity BOM Items

To use this feature, choose the option Fixed Quantity in the BOM Item.

Note: This is only applicable for BOMs of Scope Materials and when the Assembly Type is Automatic At TrackIn, Automatic At TrackOut or Explicit Long Running.

BOM Consumption Tolerances

Why does this come up?

Real life rarely matches CAD. For example, a BOM might call for 1.2m² of insulation foam, but the operator uses 1.5m² to ensure coverage, and cutting isn’t always perfect. There are numerous cases where the theoretical quantity and the actual consumed quantity are not the same.

New in 11.2 is the option to configure upper and lower tolerance limits for BOM Items. If operators use a little, it’s OK - the system registers the actual quantity, as long as it falls within the allowed range. Processes become smoother, and data reflects what really happened.

This feature ensures that the following needs are met:

• Frustrating failures or extra transactions when the consumed quantity doesn’t exactly match the theoretical value
• Operators forced to “cheat” the system or run extra steps to reconcile usage

Setting up BOM Consumption Tolerances

To use this feature, choose the option Use Tolerance at the BOM Level. Also, for each BOM Item, define the percentage values for Lower and Upper Tolerance (0% if no tolerances are applied).

Note: This is only applicable for BOMs of Scope Materials and when the Assembly Type is Manual.

Capture Information for BOM Items

Where is the pain point?

Some assembled products include externally sourced or ad-hoc items (like a cable tie, customer-supplied component, or anything with a serial number). These parts aren’t always MES materials, and perhaps the operator just needs to capture their details for traceability or compliance.

In version 11.2, you can mark the BOM Item with “Capture Information”, and the user can now enter key data (serial, batch, notes, etc.) at assembly time, associating it directly with that product and process.

Barriers removed with this feature:

• No easy way to tie serials or batch numbers to the operation
• Missing traceability for critical, non-inventoried items

Setting up Capture Information for BOM Items

To use this feature, choose the option Information Capture Required in the BOM Item, then enter text freely for Information Capture Text.

Note: This is only applicable for BOMs of Scope Materials or Parts and when the Assembly Type is Manual.

Material Assembly History

What is the real-world challenge?

Repairs and rework are inevitable in manufacturing. Typically, processes require well-defined rework flows and steps, and MES systems are designed to handle these strict scenarios, such as replacing or removing faulty components. However, in some cases, removal or replacement must happen at any time and is not tied to a specific step in production. Addressing these situations often requires extra configuration, reduced flexibility, and sometimes even disorganization when reality didn’t align with the modeled process.

What is new on 11.2 is a new Assembly History Section for each material, where information is centralized and provides flexibility. Operators see the full record of what was assembled for Explicit Long Running assemblies, and can perform assembly related operations, independent of the step the material is at, namely:

• Add more of a component if needed
• Remove excess or faulty parts
• Replace specific pieces

This has the potential to decrease workflow bottlenecks. Corrections can be made when and where the issue is found, keeping production running and records accurate.

Roadblocks cleared with this feature:

• Painful setup - dedicated flows and BOMs just for repairs
• Delays if the “repair” step wasn’t planned where it’s needed

Setting up Material Assembly History

No initial setup is required to use this feature. However, it can only be used if the Assembly Type is long-running (manual) and only once the BOM instance is closed.

Final Thoughts

Manufacturing is rarely one-size-fits-all. These latest BOM enhancements put the power and nuance back in the hands of teams building real products, not just following idealized flows.

Want to learn more? Explore our BOM User Guide BOM User Guide and Tutorial.

Author

Hi! My name is Sofia Rodrigues. ☺️

I joined the Critical Manufacturing family back in the striking year of 2020 as an MES Consultant/Functional Analyst. In 2023, I transitioned to the Product Documentation team, where I now focus on designing and creating content.

You can check me on LinkedIn

Skills: Functional Analysis | System Testing | User Training | Technical Writer

The manufacturing industry is undergoing a digital transformation, with Manufacturing Execution Systems (MES) becoming the backbone of modern smart factories. However, as we advance toward Industry 4.0, a new threat looms on the horizon: quantum computing. The cryptographic algorithms that currently protect our most sensitive manufacturing data may soon become obsolete. This isn’t a distant concern - it’s a present reality that requires immediate attention.

Why MES Systems Are Critical Targets

Manufacturing Execution Systems sit at the heart of every modern production facility, making them treasure troves of invaluable industrial property and operational intelligence. The data contained within these systems represents the crown jewels of manufacturing organizations.

MES systems document and store comprehensive production processes that reflect decades of research, development, and optimization. These systems contain detailed product recipes that define the exact specifications, ingredients, formulations, and processing parameters required to manufacture products. For pharmaceutical companies, these might include drug formulations; for semiconductor manufacturers, they contain precise etching and deposition processes; for food and beverage companies, they hold proprietary recipes and processing conditions.

The intellectual property stored in MES systems extends beyond simple recipes. These systems maintain complete process workflows that detail every step of production, from raw material handling to final packaging. This includes optimal processing temperatures, timing sequences, equipment settings, and quality control checkpoints that have been refined over years of production experience.

Real-Time Operational Data

Beyond static information, MES systems continuously collect and store real-time operational data that provides unprecedented visibility into manufacturing operations. This includes:

• Equipment performance data: Machine utilization rates, cycle times, throughput measurements, and overall equipment effectiveness (OEE) metrics
• Quality measurements: In-process quality checks, statistical process control data, defect rates, and product specifications
• Material traceability: Complete genealogy of materials and components, including supplier information, batch numbers, and processing history
• Resource allocation: Labor assignments, skill requirements, and productivity metrics

Production Intelligence and Optimization Data

Modern MES systems leverage advanced analytics and machine learning to optimize production processes. They store predictive maintenance algorithms, demand forecasting models, and process optimization parameters that give manufacturers competitive advantages. This operational intelligence enables manufacturers to reduce waste, improve yield rates, minimize downtime, and respond quickly to market demands.

These systems also maintains detailed audit trails and compliance data essential for regulated industries. For medical device manufacturers, aerospace companies, and pharmaceutical producers, this includes validation records, batch records, and documentation required for regulatory submissions.

Network and System Integration Data

As the central hub connecting shop floor equipment with enterprise systems, MES platforms contain integration configurations and network topologies. This includes access to external system credentials, communication protocols, system interfaces, network architectures, and security configurations that could be exploited if compromised.

The value of this collective data cannot be overstated. A compromised MES system could expose proprietary manufacturing processes to competitors, disrupt production operations, compromise product quality, and violate regulatory compliance requirements. This makes MES systems prime targets for industrial espionage and cyber attacks.

The Quantum Computing Threat Timeline

Quantum computing represents a fundamental shift in computational capability that threatens the cryptographic foundations of our digital infrastructure. Unlike classical computers that process information in binary bits, quantum computers leverage quantum mechanical properties like superposition and entanglement to achieve exponential speedups for specific types of problems.

Current State and Projections

The quantum threat to encryption is not a theoretical concern - it’s an approaching reality with increasingly precise timelines. Recent research and expert assessments paint a concerning picture:

• Conservative Estimates: The Chinese Academy of Sciences projects that quantum computers capable of breaking RSA-2048 encryption may emerge between 2045-2050. The MITRE analysis suggests RSA-2048 could remain secure until 2055-2060 under current technological constraints.

• Moderate Projections: Most cybersecurity experts predict quantum computers will break RSA-2048 within 15 years, with some estimates pointing to 2030 as a critical milestone. Gartner predicts RSA and ECC will become unsafe by 2029 and potentially broken by 2034.

• Aggressive Timelines: Some researchers warn of breakthrough capabilities emerging as early as 2028. A recent global survey found that 61% of security professionals believe quantum attacks will neutralize current encryption within 2-5 years.

The uncertainty in these timelines reflects the complexity of quantum computing development, but the overall trend is clear: the quantum threat is accelerating.

Algorithmic Breakthroughs

Recent developments have dramatically reduced the quantum computing resources required to break encryption. A 2025 study from Google Quantum AI researcher Craig Gidney suggests that breaking RSA-2048 encryption could be achieved in less than a week using fewer than one million noisy qubits - an order-of-magnitude reduction from previous estimates of 20 million qubits.

This reduction comes from algorithmic improvements and more efficient system designs, including approximate arithmetic and compressed error-correction layouts. Such breakthroughs demonstrate that progress in quantum computing can come not just from hardware advances, but also from software and algorithmic innovations.

The “Harvest Now, Decrypt Later” Attack

One of the most insidious aspects of the quantum threat is the “harvest now, decrypt later” attack strategy. Adversaries are currently collecting encrypted data with the intention of storing it until quantum computers become available to decrypt it.

Current Data Collection

Cybercriminals and nation-state actors are actively harvesting encrypted communications, stored databases, and backup systems containing sensitive manufacturing data. This includes:

• Encrypted MES database backups
• Secure communications between manufacturing sites
• Proprietary technical documentation
• Financial and competitive intelligence
• Customer and supplier information

Future Decryption Capabilities

Once cryptographically relevant quantum computers (CRQCs) become available, this stored data will become vulnerable to retrospective decryption. For manufacturing companies, this means that trade secrets, product formulations, and competitive intelligence collected today could be exposed in the future.

The timeline for this threat is particularly concerning for data with long-term value. Manufacturing processes, product recipes, and technological innovations often remain valuable for decades. A pharmaceutical company’s drug formulation collected today could still be commercially sensitive 20-30 years from now, well within the projected timeline for quantum computing threats.

This “store now, decrypt later” strategy creates an immediate urgency for implementing post-quantum cryptography, even before quantum computers become practically available. Organizations cannot wait until quantum computers are deployed to begin protecting their data - they must act now to prevent future exposure.

Interactive Quantum Timeline Simulation

To better understand when current encryption methods might become vulnerable, several organizations have developed online simulators and calculators that visualize the quantum threat timeline.

• IBM Quantum Experience provides access to both quantum simulators and real quantum processors, allowing users to experiment with quantum algorithms and understand their implications for cryptography. The platform includes educational resources about Shor’s algorithm and its impact on RSA encryption.

• Quantum Computing Timeline Calculators are available from various cybersecurity organizations that allow users to input different scenarios (qubit counts, error rates, algorithmic improvements) to estimate when specific encryption methods might become vulnerable.

• NIST Post-Quantum Cryptography Resources provide detailed timelines and migration guidance for transitioning to quantum-resistant algorithms. These resources include risk assessment tools and implementation roadmaps.

While there is no single definitive simulation website, these resources collectively offer interactive ways to explore the quantum timeline and understand the urgency of transitioning to post-quantum cryptography. Organizations should regularly consult these resources to stay updated on quantum computing progress and adjust their security strategies accordingly.

Critical Manufacturing’s Quantum-Safe Leadership

As the quantum threat becomes more tangible, manufacturing software providers must take proactive steps to protect their customers’ valuable data. That’s why Critical Manufacturing is at the forefront of this effort in the upcoming 11.2 release.

Version 11.2 is the first release to support Post-Quantum Cryptography, allowing customers to use X25519MLKEM768, a hybrid key exchange algorithm used in TLS 1.3 that combines the established X25519 elliptic curve with the NIST-standardized ML-KEM-768 post-quantum algorithm.

Support for TLS 1.3 with X25519MLKEM768 highlights Critical Manufacturing’s commitment to spearhead manufacturing excellence and MES innovation. Critical Manufacturing’s continuous dedication to security and secure architecture patterns, allows Critical Manufacturing MES to be one of the first MES solutions to provide Post-Quantum safe communication options.

The Imperative for Action

The convergence of quantum computing advancement and the critical nature of MES data creates an urgent imperative for the manufacturing industry. Organizations cannot afford to wait until quantum computers become mainstream to begin their post-quantum transition.

Immediate Steps

Assessment and Inventory: Manufacturers must immediately assess their current cryptographic implementations, identify vulnerable systems, and prioritize critical assets for protection.

Vendor Engagement: Work with MES providers, equipment manufacturers, and system integrators to understand their post-quantum roadmaps and timelines.

Pilot Projects: Begin testing post-quantum cryptographic implementations in non-production environments to understand performance implications and integration challenges.

Staff Training: Educate IT and OT teams about quantum threats and post-quantum cryptography to build internal expertise.

Long-term Strategy

The transition to post-quantum cryptography will be complex and lengthy, requiring careful planning and execution. Organizations should develop comprehensive strategies that address not just MES systems but entire manufacturing technology stacks including PLCs, SCADA systems, and enterprise applications. When well designed, a hybrid deployment approach with the right MES can significantly mitigate the risks of maintaining some legacy systems running on the shop-floor.

The quantum threat to manufacturing is real, imminent, and potentially devastating. However, with proper preparation and proactive adoption of post-quantum cryptographic solutions like those offered in Critical Manufacturing MES 11.2, the industry can maintain the security and integrity of its most valuable digital assets.

The question is not whether quantum computers will break current encryption - it’s whether your organization will be ready when they do.

This blog post is based on current research and industry developments as of September 2025. Quantum computing and post-quantum cryptography are rapidly evolving fields, and organizations should regularly update their threat assessments and security strategies.

Author

Hi! My name is José Pedro Silva. ✌️

I’m the R&D Director at Critical Manufacturing. Passionate about cybersecurity and everything Software Engineering.

You can find me on LinkedIn.