Case study

Name of corporation: Major

Specialization: processing with CNC technology

Range of implementation: ERP system and SCADA-MES solution

Supplier details: APLIXCOM Solutions +48 (12) 376 95 99, 607 400 534, scada-mes.com
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Description of implementation
Implementation of Infor’s ERP XPERT system and Aplixcom’s original SCADA-MES solution.

Major is a family-owned company with over 60 years of tradition, located in Tychy in Upper Silesia, Poland. It specializes in processing with CNC technology. Its main clients are automotive companies, subcontractors of such brands as:

– BMW
– Mercedes-Benz
– Volkswagen
– and other companies and subcontractors from the industry.

The company currently has over 400 employees, achieving a turnover of PLN ~60 million annually. Company owners are the ones responsible for the selection and implementation of the project on the client’s side.

Initial state, objectives:

The ERP system ensures the operability of areas like warehouse management, production (production plan, production process, technological operations), purchases and sales.

The role of Aplixcom SCADA-MES is to plan, monitor, and settle production using modules such as:

PLANER:

production plan visualization (by integrating with the ERP system via a two-way interface created by Aplixcom) with the possibility of applying changes including changeover, optimizing the production plan, the schedule, monitoring the production progress.

SCADA-MES:
enables data download from 83 machines and workstations, real-time reporting, recording of good/bad parts with defect identification, recording of downtimes, micro downtimes, and failures.

Traffic Department:

the visualization depicts the workplace group view with information on the status of the group’s work. The statuses are assigned by colours. Reporting a failure by the operator results in a change of status: failure (change to red). After repairing the failure, the employee of the traffic department finishes the order, authorized to enter the reason to end work with a comment.

CHARTS AND REPORTS:

the production plant operates in three shifts: 6 AM – 2 PM, 2 PM – 10 PM, 10 PM – 6 AM, production record tolerance from shifts is 10 min.

The charts show machine work time, operator work time, fault time, types of defects, good/bad parts, machine status, product statistics, employee statistics, machine sensors.

The created reports are: a production report, maintenance report, technician report, operator report, shift report, login report, report of running production orders, OEE.

Order history with the following data: operator records, foreman records, maintenance records, machine signals (statistics), comparison of the real time cycle to the planned one, production execution.

Current state, execution:

Aplixcom interface allows for two-way data exchange between ERP and SCADA-MES. Aplixcom SCADA-MES downloads the work plan along with additional information about TO and saves production reports to a dedicated file in the ERP system. All technological changes (e.g. multiplicity change, planned cycle time) or production orders (change of default workstation or quantity ordered) are implemented in the ERP system.

Initially, there were 64 machines and workstations in the system. The number rose to 83 until the end of the implementation stage as new ones were successively added. Currently, three years after developing the concept, we have connected 135 machines and workstations.

The company’s growth resulted in a rising number of machines. Aplixcom SCADA-MES solution is still evolving with each user request. Introducing fast changes is possible as SCADA-MES is an original solution by Aplixcom.

Currently, to meet the client’s expectations, we are preparing to launch APS,

Client benefits

After the implementation, the Client will gained:

  • EASIER PRODUCTION PLANNING

    a planner used to prepare a work plan for 83 machines for the next day (3 shifts) which took all day. Now with Aplixcom PLANER, he prepares a weekly plan in 2 hours for 137 machines and is open to dynamic changes;

  • FULL MACHINE CONTROL

    precise performance and quality of each machine, ongoing quality control – full and current quality data while working less. It is possible to immediately react to deteriorations (alarms), increase operator awareness (TV display screens in the hall – option, auto reports), which results in improved direct quality (lower risk of sending defected products, lower costs of handling complaints, lower costs of production and special transport when needing to manufacture new parts for defective products, less penalties and less lower supplier reviews via audits, which may result in losing a long-term client);

  • RELIABLE REAL-TIME PRODUCTION INFORMATION

    full knowledge about the availability and failure rate of machines, alarms – no need for a deskbound job at the workplace and personally notifying the right person, information always reaches the people responsible for the problem, multi-level notifications give control over the response time of services.

  • BETTER PERFORMANCE AND LESS WORK

    the alarm gives exact type and location of failures;

  • THE POSIBILITY OF OPTIMIZING PRODUCTION PLANNING AND USING MACHINE POTENCIAL,

    less effort managing employees transmitting production orders, updating sales information, eliminating vague situations between the production and logistics department about handling over finished products, manual counting and settlement of employees; managers focus on making strategic decisions, not on paperwork – management staff performance increases from 20% to 50%, depending on the type of production;

  • ELIMINATING PAPER DOCUMENTATION WORKFLOW

    reporting time is shortened from 40 to 10 minutes per shift allowing the foreman to spend more time supervising the hall.

  • PRECISE WORK TIME and operators' performance;

  • SAFETY – system data duplication

    higher security level in case of failure or a virus attack (malware blocking access to servers and PC), the possibility to replace the main ERP system during failure (production orders previously sent via the interface).

By successfully implementing Aplixcom SCADA-MES, the Client was able to increase production using existing machines better, accept more orders and plan controlled development.

The company’s turnover increased by 50% in the last 3 years.

After learning the types of defects, where they form and how to systematically eliminate the causes of their formation, the number of complaints reported by recipients has been significantly reduced.

The Aplixcom SCADA-MES system freed some of the staff from tedious paperwork that had to be done manually and delegate these people to more supervisory responsibilities. As our machine park has currently 137 machines, we are unable to imagine production handling without Aplixcom SCADA-MES.
Paweł Major
Contact us for details about the modern solution Aplixcom SCADA-MES in the new 2.0 version with the APS module.

Aplixcom Solutions
ul. Józefa Marcika 12
30-443 Kraków
NIP: PL954-26-62-274

Tel. +48 12 376 95 99
e-mail: biuro@scada-mes.com
e-mail: biuro@aplixcom.com