ES MES – Manufacturing Execution System

Detailed description

Data-driven manufacturing – complete insight, accurate decisions

ES MES delivers reliable, complete, and clear data collected automatically from machines and manual workstations. Effective optimization is only possible when processes are fully understood and decisions are backed by reliable data.

ES MES Market Competitiveness

• Comprehensive ES MES Implementation Full-scale implementation of ES MES involves a multi-stage process analysis, a customized deployment path tailored to each business, and extensive support covering training and maintenance. We provide ongoing assistance to our clients both before and after project completion.
• Visual Mobile Management (VMM) With Visual Mobile Management, ES MES enables effective company management from any location. VMM features an intuitive user interface fully optimized for mobile devices.
• Tailored to Client Needs The system is always customized to individual client requirements thanks to its modular architecture, rich configuration options, and a personalized approach.
• Real-Time KPI Monitoring Key performance indicators such as OEE, OLE, and downtime reasons are readily available on the main dashboard, with their status updated in real time.
• Manual Workstation Monitoring ES MES not only automatically captures production data from machinery, but also enables effective monitoring of manual workstations.
• Overall Labor Effectiveness (OLE) Calculation Tracking Overall Labor Effectiveness (OLE) allows real-time monitoring and continuous improvement of workforce productivity.
• Driving Operational Excellence Achieving operational excellence and continuous performance improvement requires effective data acquisition and smart data utilization—which is precisely what ES MES enables.
• System Scalability The system scales alongside your business, seamlessly adapting to production line changes, such as expanding product lines or adding new machinery. These updates can be quickly and easily integrated into ES MES.

VISUAL MOBILE MANAGEMENT – Managing Your Business from Anywhere

Visual Mobile Management enables you to manage your manufacturing plant from any location. It provides a clear, intuitive presentation of data optimized for mobile devices.

Benefits of Visual Mobile Management

Data visualizations are tailored to each employee. Dashboards are configured based on individual goals—taking into account job roles and responsibilities – as well as the needs of executive management.

• Clear and intuitive dashboard visuals – panel graphics (charts, summaries, etc.) are clear, clean, and easy to read.
• “Drill-down” analytical approach – the tool is built on a “drill-down” concept, allowing users to seamlessly navigate from high-level overviews to granular details.
• Instant access to key metrics on the home screen – KPIs such as OEE, OLE, downtime reasons, and more are readily available on the landing page for immediate visibility.
• Fast issue detection and real-time response – identifying critical or alarming metrics is quick and simple, enabling real-time reactions to eliminate errors and continuously streamline processes.

Business Intelligence Implementation Area

Fact- and Data-Driven Business and Investment Decisions

Business Intelligence is a module built by practitioners, for practitioners. It delivers reliable production process data, enabling rational, data-driven business decisions. It allows you to control and monitor production from multiple perspectives.

Key Features:

• raportowanie i sposób prezentacji danych wywodzący się z filozofii „operational excellence” – istotne KPI (np. OEE, OLE, przyczyny przestojów) dostępne są na stronie startowej, w formie przejrzystego, konfigurowalnego pod potrzeby użytkownika dashboardu („helicopter view”); wizualna ocena KPI według zdefiniowanych przedziałów akceptowalnych wartości (niepoprawny, poprawny, ponadprzeciętny KPI); porównywanie KPI „okres do okresu” i wskazywanie trendów (np. wzrost OEE miesiąc do miesiąca); automatyczne wyznaczanie górnych i dolnych granic kontrolnych dla KPI z zadanego okresu; dane prezentowane są zgodnie z zasadą “drill down” czyli od ogółu do szczegółu
• dane można odczytywać na urządzeniach mobilnych poprzez indywidulanie dopasowany dashboard
  
• posiada ogólny dashboard umożliwiający prezentację KPI

Obszar wdrożenia – Moduł Monitorowania

Zwiększanie wydajności maszyn

Moduł Monitorowania pozwala na kontrolowanie aktualnego stanu maszyn – ich wydajności, liczby wyprodukowanych elementów, aktualnie przetwarzanych zleceń, wylicza kluczowe wskaźniki np. OEE, OLE w czasie rzeczywistym. Pomaga znacznie zwiększyć wydajność maszyn.

Key Features:

• configurable main dashboard with basic “production” indicators (OEE, OLE) in the form of numerical values and charts
• data access “from the big picture to the detail” (location, factory, hall, machine group, machine)
• text messenger enabling sending messages to selected employees (machine operators) and resources (machines) with image attachments
• ability to explain reasons for machine downtimes (additionally, standardly this explanation takes place from operator panels)
• ability to manually set shift targets (in terms of quantity produced and changeover times)
• call module for support services (e.g., transport, process engineers)
• module for visualizing production status on TV screens

Dashboard for an individual workstation

• information on logged-in operators (first and last names) operating the machines
• information on the currently processed order ID, part ID, and operation ID
• information on machine performance relative to the shift (percentage of quantity produced / quantity planned – based on nominal output for the order per shift) and the entire order (order completion percentage: reported quantity / planned quantity within the order)
• information on the average cycle time for the machine relative to the nominal cycle time
• information on basic historical statistics for a selected machine over a chosen period (last day, week, month): OEE index, downtime reasons, operating / downtime / additional status times, working time structure, executed production orders

Reporting system presenting information regarding:

• machine operating mode (operation / downtime / power off / additional statuses)
• downtime reasons (pie and bar chart data presentation, share of individual reasons in total downtime time)
• OEE index (production resource effectiveness)
• OLE index (employee effectiveness)
• machine working time structure (in a version generated for a given period or automatically refreshed for the current shift)
• cycle time analysis (percentage comparison of actual cycle time with nominal time over a given period, for each cycle performed on the machine, with the option to show reasons for exceeding nominal cycle time)
• operator attendance at workstations (login times, working times)
• production fulfillment (summary of production quota completion over a given period, with the option to group by operator, machine, or production order)

Status presentation of monitored workstations (machines, manual stations) in the form of a plant layout map

• presentation of machines as graphic symbols with the option to reflect the spatial layout of machines on the factory floor
• clear indication of machine statuses using appropriate colors (including at least: automatic operation, downtime, setup time/TPZ, breakdown, off-line mode)
• graphical presentation of 2 metrics for a given machine (shift working time utilization, order time utilization) and textual presentation of 3 metrics for a given machine (duration of current status, number of cycles for the shift, number of cycles for the order)

Implementation Area – Order Management Module

Precise information on order execution

The Order Management Module is responsible for managing production orders at the shop-floor level. It makes dispatching orders for execution quick and simple, while significantly improving communication. It delivers reliable data on order fulfillment.

Implementation Area – Order Management Module

Precise information on order execution

The Order Management Module is responsible for managing production orders at the shop-floor level. It makes dispatching orders for execution quick and simple, while significantly improving communication. It delivers reliable data on order fulfillment.

• possibility of integration with the ERP system or automatic creation of production orders and operation orders based on order codes scanned on operator panels
• overview of the production order list
• overview of production order details
• approval of order completion in cases where the produced quantity is below the planned target
• registration of operation order statuses based on data entered on operator panels (new, started, completion request, completed)
• preview of the operator report regarding the quantity produced for a given operation order, with editing capabilities
• ability to add comments to production orders and operation orders
• ability to define nominal output and nominal changeover time for an operation order
• overview of the BOM structure for an operation order
• overview of status change history and production report history for an operation order
• correction of incorrectly entered production reports

Implementation Area – Quality Control Module

Reduction of scrap and errors – loss limitation – lower production costs

The Quality Control Module enables the creation of quality control plans and their enforcement directly at workstations. It reduces errors and waste, which in turn leads to lower production costs.

Key Features:

• ability to define an inspection plan for a product – various inspection types: incoming, in-process, final, first-piece, specifying a list of inspected parameters for individual process operations; for each operation, a list of inspected parameters including: parameter type (boolean, numerical), tolerance, measuring device, characteristic type, and measurement frequency
• entry and logging of quality control parameters (quantitative, qualitative) by production workers and quality control department staff
• automated reminders for required inspections based on the number of cycles completed by the machine
• integration with measuring devices (calipers, height gauges, etc.)
• automatic retrieval of process execution parameters from analog sensors installed on the machine (e.g., temperature, pressure)

Implementation Area – Maintenance Management Module (CMMS)

Minimization of unplanned downtime and optimal machine utilization

The Maintenance Management Module (CMMS) is designed for managing breakdowns and scheduled inspections. It provides continuous, real-time visibility into the machinery fleet. It allows you to track breakdown history – including root causes – minimize downtime, and optimize machine utilization.

Key Features:

Inspection and maintenance management for production assets

• adding and editing inspection types along with checklists for verification during the inspection, including standard execution times for individual activities
• defining scheduled maintenance/inspections for production assets (execution at specified time intervals or number of completed cycles)
• assignment of maintenance staff to inspection tasks
• comprehensive handling of inspections by maintenance operators (registration of start time, checklists of completed activities, suggested post-inspection overhauls)
• management of workshop orders (e.g., for repair or fabrication of production tooling)
• handling overhauls/refurbishments of production assets
• start screen view for maintenance personnel – to-do task list (breakdowns, inspections, overhauls)
• defining warranty periods for assets and calculating the remaining period, taking into account the duration of warranty-covered breakdowns
• assigning third-party repair services to assets
• calculating and generating MTBF, MTTR, and MTTF values

Breakdown and incident management for production assets

• comprehensive breakdown management from initial reporting to complete resolution (breakdown reporting by machine operator, acceptance of reported breakdown by maintenance staff, configurable breakdown response workflow, e.g., repair start, repair completion, acceptance or rejection by a supervisor)
• capability to notify third-party service providers
• attachment support
• breakdown history analysis for a selected asset
• generation of reported breakdowns report for a specified time period, detailing breakdown types, number of occurrences, and total duration

Implementation Area – Transparent Communication

Effective communication and production team motivation

Thanks to the HSI application and the Factory Floor TV System, fast and effective communication with machine operators is ensured. HSI enables the reporting of machine operation and order management data. Meanwhile, the Factory Floor TV System allows for the visualization of production execution status and key performance metrics.