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.
Bringing the PPC department closer to the shop floor, Manufacturing Execution software provides diversified options for the planning. Be it a line set up or a project based execution based on 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 process and machines. Work order creation and run multiple work order 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.
Shop floor dynamics are always different and unexpected. Operators and Supervisors have been given access to understand the plan and the customer priorities based on their shift and at the same time given control to dynamically reschedule plan. Option to reschedule is provided to ensure Supervisor is able to manage his challenges like Operator absenteeism, raw material availability and unexpected machine maintenance schedules. The dynamic changes reflects in the Manufacturing Execution System and all data analytics is processed accordingly.
Manufacturing Execution Solution has an edge hardware component that gets connected to the machines to acquire data directly from the PLC or from the boards for the production count and machine uptime. The master information of the Manufacturing MES Software will be used to co-relate the data received from the edge controllers to calculate the KPIs of the shop floor. The core KPIs like OEE, Capacity Utilization, Downtime with reasons are analyzed for the enhancements. All these decision making metrics are analysed at the machine, department and plant level for the daily, weekly, monthly trend to make powerful decisions.
Smart Manufacturing Execution System has inbuilt capabilities to acquire data from the machines for the rejection of the components. In addition to complete rejections, the software also can acquire data of quality metrics from Vision Inspection system via custom and standard edge protocols. The OEE Graphs depict the Quality component and also have deeper analysis for the Quality Rejection reason assessment, analysis and decision making.
Batch process like Heat Treatment, hardening and mixing process in continuous manufacturing, preparation processes and food industries play 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 overlimit 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 better outcome.
An integrated Material Store and the association of all the material delivery into the shop floor tracked with the Work Order helps management understand resource utilization with relation to the part and work order. 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 stake holders.
Smart Manufacturing Execution System is built over the highly extendable 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 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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