Specialization: processing with CNC technology
Range of implementation: ERP system and 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:
– 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:
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.
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.
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,
After the implementation, the Client will gained:
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