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.
It is possible to select only the modules needed to meet an initial requirement, but over time more modules can be added as the scope increases, to build a comprehensive Enterprise MES system.
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.
Track each order as it progresses through the factory. In the discrete world, this means production tracking at each operation in the routing whereas in the batch world, the software tracks each batch.
Machine downtime is recorded automatically 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. Reduce waste.
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 generate 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 as product is produced. Automatically use different label templates.
Track material lot numbers as they are consumed in manufacturing production processes. Improve stock accuracy, meet traceability requirements.
Enhance traceability to track serialised parts
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.