Tuning up your production

Transcription

1 Tuning up your production MES Control Room BDE MDE PZE Increasing transparency Increasing productivity Improving product quality Reducing downtimes Achieving optimum capacity Improving delivery reliability Improving use of capacity Increasing competitiveness

2 PROXIA. The company PROXIA Software AG Company Features 20 years of experience in MES Everything from one source development consultation, sales and support International Member of the COSCOM Group Our motivation The employees at PROXIA Software AG distinguish themselves by focusing on the customer's best interests, always. The most modern software developments combined with high levels of userfriendliness guarantee a virtually linear increase in added value and ensure desired productivity levels. Michael Platzner, Executive Board The PROXIA automation pyramid for optimizing manufacturing processes 2

3 MES. Economic benefits The potential of MES An MES system is a proven way of increasing productivity in a manufacturing facility. Process weaknesses are identified, targeted and eliminated. An MES system works across all platforms of a company and includes all departments in the communication process. Only an MES system can ruthlessly detect shortcomings, and only then can the available resources of a modern company be efficiently used. The advantages are obvious Solutions such as PROXIA MES can generate manufacturing and production efficiency increases of 20 to 70% over an average ROI period of 14 months. Savings potential from the use of an MES system* Production cycle times -55% Paperwork -67% Data entry times -36% Preparation times -22% Work-in-progress (WIP) -32% Errors and rejections -22% * Source: Manufacturing Execution Systems Association 3

4 MES. Target groups What is MES? Mastering processes, making information visible and correctly evaluating it, and preventing waste those are the basics for efficiency in a manufacturing and production company. An MES system creates a connection between the technically-oriented processes (machines and plants) and the commercially-oriented elements of a company. In doing so, it creates a link between management and the shop floor. MES is an instrument for controlling efficiency, effectiveness and quality in manufacturing and production. By standardizing subprocesses, PROXIA MES creates the production-related dynamic control cycles necessary for modern manufacturing that are not delivered by an ERP system. Benefits for directors/controllers Monitor efficiency Optimize capital utilization by mobilizing unused capacity Benchmarks and key indicators analysis (OEE) Benefit for manufacturing/ production managers Reduction of machine and plant downtimes Early identification of negative developments in production and manufacturing Optimization of machine and plant efficiency Benefit for quality assurance managers Monitoring and documentation of product quality Control over measures for improvement Reduction of rejectedected products Benefit for machine/plant managers Adherence with planned manufacturing times Optimum precision for repeat jobs Documentation of processes 4

5 PROXIA MES. Industry solutions Plastics industry: Automated data capture Integration of statistical quality management systems Safeguarding of material flow Chemicals industry: Procedure management Process key indicator monitoring Automated process data capture PROXIA MES competent solutions tailored to your industry As an independent MES software development company, PROXIA Software AG provides a wide range of integrated and customized solutions for optimizing processes in production and manufacturing companies. Our propriety software packages form the basis for industry-specific solutions, focusing on optimizing business performance and technical processes. Machine/plant construction: Contract manufacturing: Needs-based software structure High level of process standardization Efficient use of resources Comparison analysis of key indicators Two-way communication with the shop floor Employee scheduling Automotive industry: Seamless process documentation Precision drill-down functionality Interdepartmental planning Tool/molds construction: Detailed components documentation Detailed resources planning Assurance for repetitive processes 5

6 ERP/PPS. Communication/SAP Partner A number of projected interfaces make it possible to exchange information between PROXIA MES and the leading ERP/PPS systems. Perfect interchange with SAP PROXIA MES starts where SAP stops Integrating PROXIA MES in mysap ERP creates a system landscape in which commercial and production levels work seamlessly together. PROXIA MES has been certified by SAP with the distinction "Powered by SAP NetWeaver". PROXIA MES software can be incorporated into the SAP NetWeaver Exchange Infrastructure, an open integration solution (also SAP XI 3.0), as well as into SAP NetWeaver Portal. Incorporating SAP XI 3.0 makes it possible to integrate business processes by enabling data and information exchange between the two systems. This will provide you with detailed real-time information and avoid data redundancy. ERP and MES taking advantages of synergies to increase efficiency Flexible production requires an optimized system landscape. To achieve this, the synergies between commercial and manufacturing elements of the business need to be exploited. Software systems need to communicate with each other. The ERP and MES system must therefore be synchronized using specific process units. Intelligent software connections then ensure a seamless two-way exchange of information. Working with the same media Real-time connectors in PROXIA MES guarantee cross-system data communication. For reporting, analyses or visualizations you can access the same information on all company levels. Data redundancy becomes a thing of the past. PROXIA is a certified SAP partner. 6

7 MES. Manager A solid IT foundation with plenty of flexibility PROXIA Manager the application rack for MES modules PROXIA MES is based on a standardized system platform, PROXIA Manager. This application platform unites all PROXIA modules and forms the foundation for standardized data management. PROXIA Manager is the "application rack" into which PROXIA MES modules can be integrated. This application platform offers a wide range of standard functions that can be used in all PROXIA modules. You profit from a consistent and synchronized operating system, in which PROXIA Manager accesses all information from one central database structure. All allocations, configurations and settings can then be organized through PROXIA Manager. Changes can be made and information can be added while the MES software is running. PROXIA Manager was conceived so the software can be tailored precisely to the needs of your manu facturing and production operations, without straying from the standardized platform. PROXIA MES can therefore be updated at any time, ensuring data consistency despite shifting company demands. Additional sources of information can be added at any time and are always available to the integrated PROXIA modules. PROXIA Manager was developed using state-ofthe-art tools and is constantly being improved. It is the foundation for long-term, high-performance company solutions. Facts & standards PROXIA Manager: Standardized software platform Single software platform for customized applications Modern, upgradeable basic structure for long-term corporate concepts Consistent operation and functionality 7

8 Control room. Detailed planning The simple operation of our software is obvious in the user interface. User-specific adjustments to the interface are also an option. PROXIA Control Room action not reaction PROXIA Control Room is a tool for optimizing machine capacity. You can keep a close eye on delivery schedules in production and receive early warnings if delays are expected. PROXIA Control Room accounts for effective machine capacity, provided by shift models and utilization factors. The production planner can then simulate a variety of approaches to a solution and perform a comparative evaluation of the results. When doing so, the information is passed through the relevant order queues for manufacturing, production or assembly. Benefits & advantages PROXIA Control Room: Increased transparency in production Reduced output times Increased productivity Minimized stock levels Quicker reaction times for disruptions Minimized downtimes Minimized stock circulation levels PROXIA Control Room the best tool for stable operations PROXIA Control Room informs you in real time regarding orders, resources and materials. You can use the clear interface to simulate a variety of "rescue scenarios", then decide on the best option and implement it. The heart of PROXIA Control Room is the interactive Gantt diagram. This animated view is unique to the industry and provides an interactive simulation and planning environment that uses drag and drop. PROXIA Control Room was developed using Microsoft.NET technology and is completely free of expensive add-on components. Even the complex interactive Gantt view is a patented PROXIA development. The core of PROXIA Control Room is the optimization algorithm, which calculates the various value sets. Manufacturing orders from the ERP/PPS system are thereby compared as pegged requirements with the existing resources and capacities. Dependencies are also included in the series evaluation. The objective is to calculate optimum machine occupancy in the shortest possible time. In addition, PROXIA Control Room optimizes the output times for production orders. 8

9 PEP.. Personnel Resources Planning Planned attendances as well as possible reasons for absences can be defined in the PROXIA PEP calendar PROXIA PEP optimize your personnel planning and management There has been an unswerving trend toward increasingly flexible and customized work time models. In common production facilities, flexible shift operations and situation-based strategies in personnel planning are more the rule than the exception. These are challenges that increasing numbers of manufacturing and production operations are facing. The important thing is having the right number of employees available at the right time even on short notice so that the demand is effectively met and the various work areas are occupied by properly qualified personnel. This is where PROXIA PEP really shines. As an integral part of PROXIA MES, this software is an ideal tool for planning personnel deployment in manufacturing and production. Planning according to production orders for decisions based on facts For detailed planning of production orders, this software features PROXIA Control Room, which features shift models and employee qualifications. This allows immediate variations in shifts, for example the introduction of an additional shift for a localized production bottleneck. Using a simulation in PROXIA Control Room you can then check the results in advance of the change. This makes it possible to plan your personnel resources based on known factors, which in turn allows you to confidently make important personnel decisions. Facts & standards PROXIA PEP: Demand planning with employee qualifications Shift planning Flexibility in designing work time models 9

10 BDE. Production Data Acquisition An example of data capture with "Manufacturing" posting logic PROXIA BDE production data acquisition made easy PROXIA BDE captures the current situation in your manufacturing operation, directly at the source, either manually or automatically depending on your needs. You and your MES software are therefore always up-to-date regarding production. The primary objective in the development of PROXIA BDE was to create a solution that even PC beginners could easily operate with a self-explanatory interface. PROXIA BDE allows manual entries as well as the automated capture of machine statuses. Automated data acquisition and easy-to-configure terminal solutions for manual entry ensure that order status information is accurate. Data captured with PROXIA BDE is then available for the analysis, evaluation and visualization modules in PROXIA MES. Facts & standards PROXIA BDE: Simple operation for reliable data capture Simple configuration for messages, even when the software is running Direct communication with the control room systems Diverse options for hardware support Personnel identification with a role system BDE - a reporting system for the control room PROXIA BDE captures operations data directly at the source and delivers it to the control room based on production orders. PROXIA BDE Terminal The hardware options are plentiful, from a standard PC or industry to a data capture terminal. The terminal software can be configured as a touch display application and supports bar code readers. Standard solutions including bar codes or chips are supported for personnel identification. The BDE terminal expand it to create a comprehensive information system PROXIA BDE terminal is equipped with a role system. This allows you to use one capture location for multiple employees with different duties. The data capture interface for individual employees or roles can be configured independently and therefore serves as an interdepartmental information system for the whole company. 10

11 MDE. Automatic Data Capture & Hardware Precision monitoring of machines and plants Machine and plant disruptions need to be identified early in order to respond to a situation quickly and with the right strategy. This is where MDE enters the process and allows you to continuously monitor the current status of individual machines as well as utilization levels in production capacity. If a disruption occurs, the progress of a particular job on that machine is then quickly identified. This allows you to keep production data in the MES and PPS/ERP systems up-to-date. Automatically document process data Production processes are increasingly subjected to quality management measures. To do that, process steps need to be precisely documented. The use of MDE systems has become common in order to make the process data available automatically. PROXIA MDE for a massive range of machine types and eras PROXIA MDE is distinguished by its holistic treatment of a company's situation. Because most companies have a variety of machines and plants from a range of manufacturers and eras, it becomes necessary to employ a heterogeneous system platform for capturing machine data. The following technologies and protocols can be used in this case: OPC servers SPS and I/O modules EUROMAP 63 An alarm in the event of a disruption With PROXIA MDE you can set up a wide range of alarm scenarios, from the use of proprietary company IT infrastructure to alarms delivered via mobile phone. MDE for reliable process analyses PROXIA MDE is an important part of a robust system for process analysis. The automated capture of machine and plant conditions leads to the harmonization of data capture cycles. This online monitoring of available process data in turn provides you with high levels of information validity. Facts & standards PROXIA MDE: Support of international standards Automated data capture for high data volumes Early identification and reporting of disruptions 11

12 PZE and CAQ. Employee Timekeeping & Performance Data Capture PROXIA PZE Employee availability at a glance PROXIA PZE captures the comings and goings of employees using the data terminal and immediately checks the authorization and correct order of the postings. This posting data is then calculated and summarized in the appropriate time accounts. Missed days for holidays, illnesses or training are collected in a clearly laid out calendar. Employees can then use the posting terminal to query information such as work times, booked hours, leftover vacation days and more. All data can also be used to calculate gross wages. The system can then precisely adjust the needs of the company. Analyses provide a detailed overview of attendance/absence levels, hours worked, and availability of employees in the company. PROXIA PZE can be fully integrated into the operations data captured by PROXIA BDE. A reliable capture process for quality management The analysis, documentation and archiving of quality-related data is very important for companies that want to increase added value in production. Only high-quality products with no defects can ensure that a manufacturing company is successful. PROXIA CAQ provides a system structure that enables the capture of quality and performance data. This information can then be used for statistical analyses and reporting for integrated downstream systems (e.g. Q-DAS). Process-accompanying tests (operator self-tests) as well as incoming goods and final product tests are integral elements of PROXIA CAQ. Instead of individual software modules, a continuous process chain on a harmonized system platform is what guarantees the high level of user friendliness and consistent data flow. Facts & standards PROXIA PZE and CAQ: Access control Incentive wages/bonus system Export interfaces in wage calculation systems Test planning, test data capture, analysis and reporting Process-oriented tests, incoming goods and final product tests, Analysis and documentation Performance data capture for statistical software processes in quality assurance PROXIA partners in CAQ 12

13 MES. Monitoring The manufacturing monitor is an "online window" for production. Everything good? PROXIA Online Monitor provides the info The PROXIA Online Monitor gives you an immediate look at the current situation in your manufacturing operation. It displays operating times, downtimes, quantities and rejection values in real time. As such, the PROXIA Online Monitor is also an ideal tool for a foreman in his particular area as well as for the planner or production manager when a more global view is required. If you wish, you can even be notified of incidents via SMS or . Time bar the modern version of MES monitoring The PROXIA Online Monitor allows you to graphically display the productivity of your machines in a time bar diagram. All machine data is thus available at a glance. A foreman, for example, can see how productive the last shift was. Mobile monitoring informed at every location Mobile monitoring from the PROXIA Online Monitor can provide you with productivity, disruption and progress information even when you are not on the company premises. The early recognition of factors that negatively affect productivity can prevent expensive delays in production and assembly processes. Mobile monitoring is a web application developed according to the latest standards and it functions on any smartphone. Facts & standards PROXIA Monitoring: Early recognition of factors that negatively affect productivity Multiple-level de-escalation management Real-time display of the current situation Web-based monitoring the right information, any time and from any location High levels of security with Silverlight web applications 13

14 KPI and OEE. Key indicator verification Improve performance and efficiency using key indicators Key performance indicators, KPIs, serve as operational parameters that represent the success or failure of a company. The timeliness of the indicators of course play a very important role. They can show you whether the current planning data will fulfill the KPIs in the allotted period, so you can correct the process accordingly if necessary. The comparison of past processes with the key indicators for existing processes is also an important element of a continuous process of improvement (CPI). PROXIA KPI real-time analysis PROXIA KPI provides you with reports on all relevant process factors. The software takes automated reports from the plants and machines (MDE) as well as manual reports (BDE) and feeds them into configurable calculation formulas. Connections, control equipment and dependencies can also be flexibly configured, as can the layout of analysis data. Using drill-down functions you can also recognize immediately where the "problems" in your process or company are being caused. OEE Monitor determining productivity Facts & standards PROXIA KPI and OEE: Process assessments as a basis for continuous process improvement (CPI) Standardized calculation mathematics and definitions according to VDMA unit information sheet DIN High-performance drill-down function for localizing disruptive factors in processes Online key indicators (OEE) Precise information regarding machine capacity and production efficiency are key in successfully and continuously optimizing your processes. The OEE value is one of the most important indicators for machine, production line and production cluster performance. It directly shows losses in efficiency, which then makes it possible to compare machines independently of the product in question. The PROXIA OEE Monitor is a production-wide evaluation module that shows the current OEE value. All relevant personnel and departments are informed in real time and can react immediately. 14

15 MES in practice. Customer feedback Ferdinand Bilstein GmbH & Co. KG "With the PROXIA MES system we always know well in advance where problems are occurring and can react accordingly, without deadline pressure and all of its associated drawbacks. The MDE/BDE solution provides us with more transparency in manufacturing, which in turn enables us to better use our capacity." Steeltec AG Schweiz "PROXIA MES allows us to quickly and efficiently determine all of the relevant key indicators in our manufacturing operation. This provides us with optimum production planning, which ultimately resulted in clearly measurable and shortened delivery times. With PROXIA MES we are equipped for the long term!" Reis Robotics GmbH & Co. KG "With the control room software we can run our entire production operation more quickly and securely. Combined with the MDE/BDE modules we brought "light into the darkness" and were able to improve throughput by 40%. Additional synergy effects and a significant improvement in material flow and logistics processes then helped us to quickly achieve a satisfactory ROI." Salzgitter Service und Technik GmbH "Our goals for implementing the MES system were to minimize stock, produce more efficiently and reduce throughput times. Thanks to the continuous PROXIA MES solution we are now equipped to combat fluctuations in the economy and we are more competitive. On top of that, it only took 6 months from the decision to the productive system. Superb!" 15

16 PROXIA. Worldwide PROXIA Software AG Germany Headquarters Anzinger Str. 5 D Ebersberg Telefon: +49 (0) Telefax: +49 (0) Braunschweig Office Kaulenbusch 1a D Braunschweig Telefon: +49 (0) Telefax: +49 (0) France Headquarters 8, rue des Lilas - BP F Mundolsheim CEDEX Telefon: +33 (0) Telefax: +33 (0) Poland Headquarters ul. Budowlanych 59 PL Tychy Telefon: Telefax: South-West Office Mollenbachstr. 37 D Leonberg Telefon: +49 (0) Telefax: +49 (0) Austria Headquarters Europaring F15, Campus 21 A-2345 Brunn am Gebirge Telefon: +43 (0) Telefax: +43 (0) North American Headquarters Kincey Avenue, Suite 142, Huntersville, NC Telefax: West Office Gottlieb-Daimler-Straße 2 D Holzwickede/Dortmund Telefon: +49 (0) Telefax: +49 (0) Switzerland Headquarters Industriepark Logistikcenter 1 CH-6246 Altishofen Telefon: +41 (0) Telefax: +41 (0) Czech Republic Headquarters Chlumecká 1539/7 CZ Praha-Kyje Telefon: Telefax: