Our client in the glass industry required a Manufacturing Execution System (MES) implementation. We began by gathering sufficient information, understanding, analyzing and consolidating business requirements and then translating these into functional and technical specifications. To do this, we customized and configured models of the projected IT solutions necessary for the MES.
We needed modern production machinery to match the increased demands on organizational concepts and planning and control software. To meet these fast processing times, production processes were to be optimally planned and controlled. Additionally, scalable software systems and integrated solutions were key for an optimized production environment.
The computerized MES was the optimal solution for this manufacturing facility meaning predecessor steps in model configuration as well as the set-up of reporting and data mining tools, necessary components for the projected system.
Other implemented solutions included:
These new systems provided our client with multiple, in depth areas regarding: product life cycle, order executing and dispatch, overall equipment effectiveness, data acquisition, and other manufacturing processes. To integrate these systems, implementation of a maintenance management system interfaced with SAP in charge of the whole scope, from functional analysis to roll-out was also added to the solution.
Our highly flexible PPS solution allowed our team to plan and control even the most highly sophisticated, multi-stepped production processes. Combining this with other basis improvements such as campaign planning and scheduling algorithms greatly facilitated the work of production managers and floor staff.
The MES allowed for the tracking of materials into finished products. This analysis provides useful insight into production output, potential optimization procedures, and other area of improvement. The new MES resulted in reduced waste, accurate cost analysis, reduced inventory, and other efficient advancements.
The system allowed for order processing and gave sales staff the ability to answer customer enquiries quickly and reliably; the delivery process can also be organized and adjusted if necessary. Flexible adaptation of process steps allowed for specific preparation needs. Predefined planning and control processes throughout preparation and production allowed for increased quality, speed, and results were achieved while reducing costs.