Roll Manufacturing & Converting Excellence GRASS MANUFACTURING.EXCELLENCE.

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1 Y O U R M A N U F A C T U R I N G E X E C U T I O N S Y S T E M Roll Manufacturing & Converting Excellence GRASS MANUFACTURING.EXCELLENCE.

2 ABOUT US Being the industry specialist we exactly know and understand your specific requirements. We speak your language and you don t need to train our consultants before they understand your processes and add the value you expect. Success arises from experience and best practices, paired with individuality and the spirit of innovation. For now more than 30 years Grass GmbH is a proven industry specialist and a leading supplier for manufacturing-related standard software and consulting services within the roll manufacturing and converting industry. We offer the perfect MES-solution for your rollspecific manufacturing and converting processes. Furthermore we offer respective consulting services to identify additional productivity potentials within your company. In addition our success is based on a culture of partnership and collaboration with our customers and suppliers and on our specific and customer-centric solution. Our powerful and proven Manufacturing Execution System COAGO increases transparency and efficiency of your manufacturing and converting processes around films, papers, textiles, nonwovens or rolls, webs, formats and sheets. Highly reputable clients rely on our software solution and consulting expertise in regard to their manufacturing success. Page 2

3 References Bilcare Research Constantia Patz Kalle SUCCESSFUL WORLDWIDE Klöckner Pentaplast Mondi Renolit SE Already users located on nearly 25 sites in Germany, Austria, Switzerland, Spain, Portugal, Thailand, China, Russia, Canada and the USA are supported by our Manufacturing Execution System COAGO. We are proud to include leading manufacturers of food and pharmaceutical films, high-tech barrier films, laminating films, label films, decor, furniture and window films, technical films, cup and blister lidding and packaging films in our client repertoire. Surely many of them are very familiar to you, most of them either as clients, suppliers and/or competitors. Consulted Manufactures Germany, Austria, Switzerland, Spain, Portugal, Thailand, China, Russia, Canada, USA Page 3

4 SAFE AND SUSTAINABLE INVESTMENT Clear Industry Focus Stability and Independence Future Viability and Security of Investment Company/Product Strategy Industry Expertise Investing in a new MES-solution is a key component of a productionrelated IT-strategy. These investments usually reach significant dimensions which shouldn t be questioned after two or three years but have a sustainable strategic focus. To secure important investments for the future you need partners, technologies and product strategies that are proven and tested in the industry. Once you have reached strategic potentials for future development of your enterprise your goal to invest in a sustainable solution is achieved. As an independent partner, we have successfully and fully dedicated ourselves to serve the roll manufacturing industry. Our entire company and product strategy is targeted exclusively to your industry to meet your requirements - the best preconditions for sustainable success of your MES-investments. Page 4

5 MORE ADDED VALUE WITH COAGO Production is one of the most important links in the entire value chain. The foundation for economic success is built on factors like quality, ontime-delivery and cost-optimized performance. A system which focusses on sustainably supporting and enhancing processes of your value chain needs to be adjusted exactly according to the production-related, industry-specific requirements of your enterprise. It has to be able to cope with your specific production requirements and perfectly enhance and support your manufacturing processes as well. COAGO the MES for your industry made by specialists. COAGO is the industry solution targeted to all details and varieties of the roll manufacturing and converting industry. You can be sure that your specific requirements will be met through COAGO-solutions, exclusively designed for your industry and your specifications. True to the motto: made by specialists. Page 5

6 BENEFITS FOR EVERYONE WITHIN YOUR COMPANY Top Management Top Management is able to transparently access all decision relevant production data at any time and make decisions based on reliable data, facts and figures. Production Management Controlling Planning Production Management is able to permanently supervise the recent situation of production online and has the chance to intervene before errors may multiply. Key figures reveal possibilities for optimization and measures can be evaluated according to the effect they render. Controlling receives via safe and powerful interfaces reliable and consistent feedback of cost relevant parameters. The Planning Department is able to create an optimized sequence of orders, monitor the production progress online and schedules can be adjusted according to the actual situation on the shop floor. Everything Everywhere Anytime Planning Contro Page 6

7 l Monitor Transparency E ficiency Excellence EFFICIENCY AND EXCELLENCE THROUGH TRANSPARENCY The Quality Management Department is able to model the inspection planning and handle data aquisition using an integrated system. This seamless integration of your production processes leads to higher speed and increases transparency. Logistics gain speed. The WIP stock is reduced, work stations are supplied with the right materials and finished goods are removed according to schedule. Quality Management Logistics Customer Service is able to inform customers about the status of the order at any time. On-time-delivery and customer satisfaction increase. The operator is able to focus on his machine and his product. He receives all relevant information in a clear format and the system supports him when processing the order. Customer Service Worker Page 7

8 ALL PROCESSES IN ONe MES Goods receipt such as rolls, formats, raw materials and buy-ins A complete solution from goods receipt to palettes ready-to-ship. Mixing e.g. of granulates, colors, pastes or fibers Mother roll manufacturing e.g. at the calander, extruder or in the co-extrusion, at paper mills or on nonwoven lines. Converting such as coating, laminating, printing, embossing or stretching Goods Receipt Mixing Mother Rolls Converting Processing Packaging Processing e.g. roll or format slitters, punching, bags converting Packaging e.g. palettizing, labeling and shipping Re-Work e.g. re-winding, splicing Recycling e.g. grinding and re-compounding Parallel to the Manufacturing Process Detailed production planning, quality management, machine and process data collection, specification management, reporting and controlling Page 8

9 A HOMOGENE SOLUTION FOR YOUR PRODUCTION COAGO offers sophisticated modules for the entire value chain of the roll manufacturing and roll converting industry. Regarding this complete scope of features of a state of the art MESsolution, COAGO provides a complete range of modules. It s typically linked between common ERP-systems and the machine control or PLC. Maintenance Management Printouts & Labels Roll Management Service & Admin Documents Controlling & Reporting Logistics & Warehouse Interfaces SPECS Workflow Management SPC Traceability CAQ Stock Replication & ATP Scheduling & Planning Edge Trim Shop Floor Data Process Data Machine Data Order Combination Order & Phase Monitoring Schift Plan Page 9

10 Fine PLANNING. DATA HANDLING. Improvement through planning and actual data entry. Detailed Planning Planning board with graphic visualization Dispatching and replanning of orders Combining or splitting of orders and operations Plausibility checks and monitoring in case of replanning Order-list visualization Electronic Order Papers Order information Specifications e.g. quantity, time, performance Integrated documents Operational Data Collection Reporting of order, machine and staff times Quantities report e.g. locks, scrap, good materials Catalog granularity in times and quantities Text captioning for rolls/manufactured objects, QC and order Continuous backflush to the ERP-system Roll Management Dimensional modifications Plausibility checks of length, width and weight Qualified reports of rolls or formats such as lockings, scrap, by-products Integration and recording of inspection results Text capturing of manufacturing objects and orders Page 10

11 CAQ. TRACKING. REPORTING. Identify opportunities. Realize potentials. Quality Management Inspection planning Inspection results aquisition Inspection device integration Analyses, evaluations, reportings Certificates and accompanying documents Batch-Tracking Multi-directional tracking Change of tracking direction through drag & drop, e.g. from the raw material to all customers and back Flexible tracking start at any point of the production process, e. g order, raw materials, manufacturing processes, rolls, formats, palettes, customers Export and print results Drill-down into further modules, such as roll management, CAQ Reporting & Controlling Standardized reporting system, such as OEE, quantities, times, quality, machine or process data Variable parameter control management of reports Chart or table visualization Export as graphic or raw data Machine overview, operation views Page 11

12 MDA & PDA. SPECS. LOGISTICS. Design, supervise and optimize processes. Machine & Process Data Integration of the PLC Integration of mixing area and mixing devices Integration of inspection devices such as camera based web monitoring, OCS, black spot detection, thickness measurement Roll visualization and markings Specification Management Machine datasheet and operation values Check lists and plans e.g. cleaning plans, machine settings Manual or automated result recording Notification of exceptional situations or discrepancies Reporting and trending Workflow Management Design and direct context-related workflows Make information transparent Avoid mistakes Process stability Logistics & Storage Management Event-driven transportation orders Integration of forklift systems and self-guiding transport systems WIP-storage management Material stock overview and inventory support Picking and putaway strategies Page 12

13 ALLROUND SERVICE, EXCEPTIONAL SUPPORT. Support 24/7 availability and on-call service for all time zones Experienced support staff with customer know-how Internet-based support and customer service center Call monitoring and tracking Individual service-level agreements Maintenance 100% industry focus Continuous improvement Focused product development Value Added Services Consulting in hardware-sizing and selection Database management and administration Virtualization Network analysis and performance enhancement Realization of backup systems and emergency concepts Server installation and maintenance Development of a complete COAGO environment Our service is as highly available as the production of our customers. We are there for you whenever you need us. Page 13

14 NOTHING IS MORE CONVINCING THAN SUCCESS Successful software projects in the manufacturing sector can only be guaranteed by a partner who has gained extensive experience within the value added processes of his customers and their up- and downstream functions and systems. Furthermore our employees distinguish themselves by profound knowledge of methods and efficient project management. Our customers say it is pleasantly simple to work with us closely. They appreciate our distinctive knowledge and the capability of collaborating in a professional and innovative way. Image sources:: Tino Neitz, AA+W, Kaarsten, Victor Tongdee, krsmanovic, Guido Vrola, contrastwerkstatt, VRD, K.-U. Häßler, Minerva Studio, michaeljung TASPP, Laurentiu Iordache, Moreno Soppelsa, arahan, cultura2, fotoklatka, Kurhan, RGtimeline, jannoon028, industrieblick, Janina Dierks, FotolEdharFotolEdhar, Klaus Eppele - Fotolia.com. Maschine, Reifenhäuser GmbH & Co. KG Maschinenfabrik, Bilcare Research»Stringent project management, a highly qualified team and many years of industry knowledge. These are the key factors that Grass GmbH used to successfully execute MES and Lean projects within a minimum of time. We were highly satisfied. Thank you.«martin Klinkert, CIO, Renolit SE Page 14

15 ROUND ON OFFER Competitiveness begins in your production facilities - with lean processes, high utilization of your machines and equipment, avoiding waste and employees focusing on the excellence of their products with a zero error tolerance. Moreover, with tools that show you at a glance where you are and in what direction you are currently heading. You detect errors before they happen and are able to intervene before they may disperse and affect other processes. Rely on our long experience with rolls, formats and sheets. We offer with COAGO we offer a MES-solution, which has set industry standards and consulting services that reveal productivity potentials aimed Goods receipt at increasing your performance. Recipes Mixer Volumetric Flexography Recycling Co-Extruder Secure your company a place in the future. Pulper Gravimetric Calender Sheetfed Printing Regrinder Paper machine Coating Rolls Formats COAGO MES Industry Software Sheets Extruder Gravure press Web materials Winder Embossing Laminating Rework Quality Bags converting Slitter Traceability Size sheeter Punching Automation Reporting Packing Labeling Logistics Page 15

16 2013 Grass GmbH. All Rights Reserved. COAGO - e Grass GmbH Kreuzstraße Bad Kreuznach Germany Fon: Fax: info@grass-gmbh.de