The Shopfloor-Online MES software platform comprises 26 independent modules across the 4 main areas of manufacturing operations, as defined by the ISA-95 model.
Organisations can select the MES software modules needed to meet an initial requirement. Over time, more modules can be added to build a comprehensive Enterprise MES system.
Manufacturing Execution System (MES) software is a system “to manage, monitor and synchronise the execution of real-time, physical processes involved in transforming raw materials into intermediate and/or finished goods.” Gartner
Lighthouse Systems and Shopfloor-Online, its MES software, were recognised with an "Honorable Mention" in the 2021 Gartner Magic Quadrant for Manufacturing Execution Systems report.
Plan production orders, determine start and end dates and assess capacity and ability to meet deadlines. Communicate the plan to production with real-time feedback as production executes.
Production tracking for batch and discrete manufacturing orders. Track production order progress through the factory for each manufacturing operation or for each batch process.
Machine downtime is recorded by direct connection to the PLCs controlling production processes (or manually where such connections are not possible); downtime analysis and reporting then identifies opportunities for improvement.
Record production quantities either manually at the end of the production run, or in real-time, by picking up counts from the production lines and equipment. Calculate KPIs such as production efficiency and actual cycle times.
Record production waste & scrap manually or automatically. Analyse waste with real-time data capture to help reduce losses.
Collect and analyse production performance data in the software module that calculates OEE for each production process. Improve production efficiency and accountability.
Improve communications across all groups within manufacturing, e.g. hand-over between crews on shift change, team and management reporting, operators back to planning. Improve traceability.
Track where labour hours have been spent. Define target manpower on the product routing. Control costs. Improve exception management. Support traceability.
Model the execution of the manufacturing process in the MES. Identify all the steps that should be followed, capture the progress of the job as it executes and keep a detailed record of the production process.
Quality management software allowing data to be collected at the line or in the lab. Issue reminders to operatives, enforce the quality control system, respond to issues and measure conformance.
The tools to measure process variation, understand process capability and reduce the impact of process variation. Visualise SPC charts and add SPC data to conformance certificates.
Monitor process parameters with the built-in historian of Shopfloor-Online MES. Chart data. Gain deeper insight into the process. Enhance traceability.
Quickly access all the documents you need e.g. SOPs, CAD drawings, product specification documents, quality procedures. Ensure everyone is working from the latest revision.
Speed up the resolution of non-conformances. Record, track and document non-conformances through to resolution.
Record, investigate and manage customer complaints. Improve the speed of resolution. Develop accountability and best practice. Improve customer satisfaction.
Drive greater suppliers’ performance. Record, investigate and manage supplier non-conformances. Create a paperless record to support the complaint. Manage claims.
Create, track and manage lots of materials/handling units, from raw materials, to semi-finished and finished goods to enable traceability.
Automatically print bar-code labels on your own templates. Use labels to implement traceability.
Track lot traceability as materials are consumed in the manufacturing process. Improve stock accuracy and meet traceability requirements.
Ensure traceability of manufacturing operations at serialised parts level through to finished goods. Achieve compliance with inventory updates in real-time.
Manage in-bound & out-bound deliveries. Capture traceability data at shipping. Manage internal material movement orders (replenishment) and deliveries. Track orders and materials in the warehouse. Link with the ERP.
Improve Enterprise Asset Management. Manage manufacturing assets through their life cycle.
Optimise maintenance activities: create maintenance procedures. Plan and manage maintenance work. Record work done, spare parts used.
Speed up response to breakdowns. Manage repair work. Enforce procedures.
Monitor tool life. Track tools used in the process. Develop detailed tool histories. Make better decisions regarding tool use and maintenance.
Record energy and resource consumption. Know where your energy goes. Reduce energy losses.