The market for IT systems used in manufacturing enterprises is constantly growing. More and more companies are joining the ranks of those implementing Industry 4.0 technologies and solutions. The most common reasons are the desire to automate certain processes, increase production efficiency, and minimize costs. An investment in Industry 4.0 technologies, like any investment, should bring the highest possible return.
Implementing several different systems responsible for production planning and scheduling, maintenance support, data collection from machines, and production execution is not an optimal decision, both in terms of finances and time.
Wouldn't it be better to implement one complete system, which, combined with an ERP system, would allow for the management of all production-related areas?
There are many classes of systems aimed at improving production and related processes. The most popular of these are:
- APS (Advanced Planning and Scheduling) – a class of IT systems that enables automatic production planning using advanced algorithms and optimization functions, such as minimizing changeovers on a specific group of machines.
- CMMS (Computerized Maintenance Management System) – a class of IT systems designed to support the maintenance department. They allow for automatic failure notifications, the creation of maintenance and repair schedules for machines, and the collection and visualization of data on breakdowns and micro-downtime.
- MES (Manufacturing Execution Systems) – a software tool used for managing production in a broad sense. It allows for real-time data collection from production, making it easier to respond to errors and unwanted situations.
Each of the above systems undoubtedly adds value to the enterprise and enables continuous improvement of production, in line with Kaizen and Lean Manufacturing philosophies. However, implementing these solutions as separate software can complicate life for production employees and, above all, for the IT team. It’s also far from an optimal financial decision.
Wouldn’t it be simpler to implement one tool that allows for proper planning, optimization, monitoring, and accounting for production?
The proprietary Lean Manufacturing System platform, based on the proven and long-standing SCADA-MES system, includes modules that improve communication between employees from:
- production,
- planning,
- maintenance,
- quality control,
- human resources,
- management.
Aplixcom SCADA-MES integrates with the ERP system to exchange data on production orders. These data can also be manually entered into the system or imported from an XML file.
On the Gantt chart, the planner can arrange the production schedule using optimization functions such as minimizing changeovers, optimizing material availability, or minimizing breaks between operations. If machines are connected to the system, the planner can see the current progress of ongoing operations and their projected completion, which helps in making better decisions.
Information on scheduled production orders is sent to operator panels (tablets, industrial computers), where operators can log their work. These panels can also display electronic documentation, helping reduce paper document circulation in the company. Via the panel, an operator can:
- log quality control results,
- generate a call (SMS/email) to any employee,
- report a failure,
- request materials.
Maintenance staff record their takeover of a failure and the time it was repaired, providing complete data on their work. The planning calendar also displays scheduled machine repairs and maintenance, as well as any breakdowns. The maintenance module offers a range of functionalities related to tool management.
An equally important aspect is employee management. The Employee Matrix module allows the definition of employee skills and the competencies required to perform specific operations. The shift supervisor can assign employees to operations they are to perform, providing an overview of employee workloads and planned availability.
For management, the most important modules are Dashboards and Analyses & Reports.
Efficiency Dashboards show the current production situation, including the status of workstations (work/failure/changeover/idle), production progress, production quality, and other data. For the sales department, the Orders Dashboard is especially useful, showing the progress of current production orders. This allows salespeople, when asked by a customer about the status of their order, to check the progress themselves without involving others.
The Aplixcom SCADA-MES system has many more features, too numerous to list in a single article.
However, the biggest advantage is not just the system itself and its extensive functionality, but the experienced consultants at Aplixcom, who have been implementing ERP and SCADA-MES systems in production for over 20 years. Additionally, Aplixcom is the creator of this solution, meaning it can be modified and tailored to meet the specific needs of clients. We understand that every industry and every production facility has its own specificity, so no two implementations of our system are the same.
Summary
Are you curious whether our solution and experienced consultants can help you take the next step toward Industry 4.0?
Leave your contact details in the contact form, and we will reach out to see if we can help.
Trusted by brands like Ronal, Faurecia, Borg-Automotive, Nifco, Stako, Izo-Blok, and many others.
