Production Counting - Shopfloor-Online Production
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 the Production Counting 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.
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What are the benefits of the Production Counting module?
- 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).
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
Enhance Production Counting software module by combining it with others from the MES software suite:
- Downtime, Waste, and OEE system - 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
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