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Production Counting

Production Counting

Know where you are with a software application that counts production in real-time

 

Accurately count production in real-time and improve effectiveness with Shopfloor-Online MES

Counting production can be difficult in high speed processes. Knowing exactly how far to go to complete the order and avoid over-making is another problem. Use this module of the MES software to:
  • Record production in real-time, by connecting via OPC, to the production equipment
  • Alternatively record production manually at the end of every production run or shift
  • Work out the production speed  and calculate accurate cycle times
  • Track the progress of each order as it is being made and how much is left to make
  • Collect counts in different units of measure e.g. cycles, pieces, Kg, meters and pick up multiple counts from multiple points (machines) in the process.
 

Record quantities produced

  • Manually record quantities – at the end of each production run or shift or as it occurs 
  • Automatically record quantities – by connecting directly to the machines to pick up counters like cycles, pieces etc. 
  • Where you can’t take data from existing equipment, it is possible to install inexpensive PLCs to capture production counts
  • Dual-mode - combine manual and automated data collection for more flexibility
  • Invest in automatic data collection where the payback is likely, but with the benefit of a plant-wide unified recording system

Add-On data capture PLCs

  • Where you can’t take data from existing equipment, we can install inexpensive ancillary PLCs to capture production counts

Reporting

  • Actual cycle time vs. Target cycle time (best demonstrated cycle time)
  • Production speeds
  • KPIs such as Production Efficiency and Actual Cycle Time
  • Avoid over-making – accurately count production as the order approaches completion
  • Improve effectiveness – optimise Operators’ time by collecting data automatically and reduce errors
  • Visibility –   track progress against the order during production
  • React faster – make the factory more agile and responsive when problems occur
  • Continuous Improvement – know actual cycle times and measure production efficiency throughout the plant. Find the best ever cycle time (golden runs).

Enhance Production Counting software module by combining it with others from the MES software suite:

  • Downtime, Waste, and OEE - to generate real-time OEE reports and other KPIs.
  • Waste
  • Scheduling - to anticipate when the production run will end and the impact on the schedule
  • Asset Register – to develop life time piece or cycle counts for each machine
  • Maintenance – to use piece or cycle counts to trigger planned maintenance
  • Energy – to calculate energy per piece