Establish a fully connected, paperless factory that keeps every stakeholder aligned from planning through delivery. With a digitally enabled system supporting end-to-end operations, M2M (Machine-to-Machine) communication enhances automation and productivity, achieving efficiency gains with minimal cost impact.
Bridging the PPC department closer to the shop floor is crucial, as efficient planning forms the foundation of a streamlined manufacturing process. Our Manufacturing Execution Software offers diverse planning options to optimize operations. Be it a line set up or a project based execution based on an operation order, you can configure the software to create the plan based on the machine availability. Plan generation can be automated based on the master information like cycle time, process for a particular part based on the work order. Flexibility to plan based on individual processes and machines. Work order creation and run multiple work orders in parallel with option to pause and resume. The Work order based production report keeps every stake holder in sync to keep the customer informed of the delivery timeline.
Production plan execution requires adaptability due to the unpredictable nature of shop floor dynamics. To address these challenges effectively, empowering workers with the right tools is essential. Our MES software enables Operators and Supervisors to easily access the production plan, understand customer priorities based on their shift, and dynamically reschedule tasks when necessary. This flexibility allows Supervisors to manage unexpected situations such as operator absenteeism, raw material shortages, and machine maintenance. Any changes made are immediately reflected in the Manufacturing Execution System, ensuring that all data analytics are updated in real-time to support better decision-making.
Acquiring data directly from the PLC or machine boards for production count and machine uptime is crucial to optimizing the production process. Our Manufacturing Execution Solution features an edge hardware component that connects directly to the machines for seamless data acquisition. This data is then correlated with the master information in the MES software to calculate key performance indicators (KPIs) for the shop floor. Core KPIs such as OEE, Capacity Utilization, and Downtime with reasons are analyzed to identify areas for improvement. These metrics are reviewed at the machine, department, and plant levels, and trends are tracked daily, weekly, and monthly to support informed decision-making.
Quality being an essential factor in product excellence, our Smart Manufacturing Execution System is equipped with inbuilt capabilities to acquire and manage data related to component rejections. The software allows manual entry of rejected count along with the reasons for rejection, ensuring comprehensive quality tracking. The OEE Graphs depict the Quality component and also provide deeper analysis for the Quality Rejection reason assessment, analysis, and decision-making.
Batch processes like Heat Treatment, hardening, and mixing processes in continuous manufacturing, preparation processes, and food industries play an important role in the quality outcome of the parts. MES Software can extract data from the machines by interfacing with the HMI and PLC to acquire these information on a timely fashion and plot it as SPC (Statistical Process Control) charts against the time of the cycle to ensure that the set and the actual values are not running over-limit above the standard levels. The live data can be used to run prediction analysis with the historical quality outcome to dynamically change set values as needed for a better outcome.
Understanding resource utilization in relation to parts and work orders is essential for optimizing operational processes. An integrated material store, along with tracking material deliveries to the shop floor through the Work Order, helps management achieve this. A completely streamlined request-delivery methodology across the shop floor and between departments assists having control of the Inventory movement. Store Inwards and Finished Goods help end-to-end tracking of materials. Manufacturing Resource planning, an add on over the Manufacturing Execution System helps predict the timing of the material need based on the orders, WIP, Finished Goods and keep Vendor lead time and suggest order placement.
Manufacturing execution Solution support automated and manual movement of the WIP Inventory. For line setup, the automated movement of WIP shows the availability of the raw material for the next process. The movement happens based on the process order defined for the particular part and also based on the Work order. The tag number of a batch or an individual component can be traced along with the process parameter, Quality metrics, in reference to the machine and the operator at any point of time.
Smart Manufacturing Systems will provide detailed dashboards for each stakeholder, empowering them with real-time valuable insights.
Our Smart Manufacturing Execution System is a versatile solution for companies of all sizes, from large enterprises to small businesses, built on a highly extensible and scalable IoT platform. The platform is micro services based and can scale to high data throughput with precision of delivery. The Platform can be deployed on premise or on a private cloud as required for the Enterprise customers. The application can be customized and extended to cater to the advanced needs of the large Factories. Keeping MQTT as the core communication between the machines and the central server, the MES Production Software comes with the required edge gateways to collect and communicate data.
For MSME, the cloud MES Solution with the complete production monitoring is offered as an on-demand SaaS application.
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