This difference mean that there are more chances to automate the entire process eventually, which in turn would have a huge impact on the manufacturing industry as a whole.

The idea behind smart factory is to make goods with the maximum amount of automation possible, and not just automation at certain production stages. In fact, manufacturers are working towards full automation. Unlike the traditional factories that require human interaction, smart factories don’t need any human interaction during production because the whole process is automated.s that it will become the nature of businesses to create and control automation systems, without being limited by budgets or resources.

The industry moves toward integrating advanced technologies into the manufacturing processes using big data, artificial intelligence and robotics. The goal is to produce quality parts with less manpower and at any location in the world.

In this setting there is a better workplace for employees; depending on the application level of automation, it is possible to reduce worker participation in repetitive tasks by 80% and increase all parameters including OEE.

The Master Batch Record is designed to ensure that all proper ingredients are added and that each step in the process is completed and documented.

Master Batch Records MBR (called Master Production Records MPR or Master Manufacturing Formulas MMF) are detailed manufacturing instructions. Each unique recipe and batch size must have its own MBR.

The master batch record should require the following information, for example:

• Product name identification.

• A bill of materials detailing the weight, measure, or number of each ingredient needed to make the batch.

• A list of equipment.

• A list of components.

• A statement of theoretical yield at each stage of the manufacturing process.

• The expected yield of the finished product.

• Detailed instructions for each condition in the manufacturing process.

• Sampling and testing procedures.

• Instructions for manual operations.

• Discrepancy data

These documented instructions are required for each unique recipe and batch size to ensure standardization and repeatability of the process every time. Because the MBR is the original template from which copies are taken, it is not filled out during the manufacturing process. It is associated with a production number or part number, but is not associated with any specific lot number.

Computerised Master Batch Record

A computerised Master Batch Record is a modernised approach to manufacturing record-keeping, integrating advanced software solutions into the production process. This digital transformation revolutionises how manufacturing operations are managed, providing a comprehensive system for creating, managing, and optimising production workflows.

Key Features and Benefits

1. Real-time Data Integration: Digital MBR seamlessly integrates with various manufacturing systems, enabling real-time data exchange. This connectivity ensures that up-to-date information is readily available to manufacturing personnel, enhancing decision-making and issue resolution.
2. Error Reduction: Automation within Digital MBR significantly reduces the risk of human error by automating data entry and incorporating validation checks. This results in greater consistency and higher product quality.
3. Efficient Recipe Management: Digital MBR simplifies the management of multiple recipes for different products and batch sizes. Manufacturers can create, update, and maintain recipes effortlessly, ensuring accurate production every time.
4. Version Control: Robust version control capabilities in DMBR systems guarantee that manufacturing instructions comply with the latest regulations. Manufacturers can adapt swiftly to changing requirements without compromising compliance.
5. Electronic Signatures and Audit Trails: Computerised MBR facilitates electronic signatures and maintains comprehensive audit trails. This feature is vital for tracking and authenticating critical actions, aiding regulatory compliance, and supporting investigations.

The EBR record also demonstrates that the organization properly handles and records all critical steps in the production of each batch of product, whether entered electronically or manually. This record contains data related to operators, manufacturing process, equipment, materials, and supplies. It may also contain data from laboratory information management systems (LIMS), enterprise resource planning (ERP), process control systems (PCS) and others.

Unlike analog, paper-based, defined batch records, electronic batch records enable an organization to see the benefits of improved data integrity and accuracy, streamlined processes and efficient operations.

Optimizing these processes provides better resource management, improved inventory management and reduced material waste – all of which positively impact the bottom line of the operation.

It is critical to assess the following areas:

• People (organizational culture)

• Business processes

• Technology

The acronym EBR, can also refer to an end-to-end information system that allows for the electronic recording of batch records as a copy or reproduction from a master batch record. (MBR – Master Batch Record).

Industry 1.0 – human labor is replaced by steam machines.

Industry 2.0 – humanity begins mass production using electricity.

Industry 3.0 – the first automation based on computer systems occurs.

Continuous automation of old manufacturing and industrial methods progresses along with the use of current smart technologies, large-scale machine-to-machine (M2M) communications, and the Internet of Things. The overall process is translating into major changes in the way the global manufacturing and supply chain network operates. Increased automation, better communication and self-monitoring, and the use of intelligent equipment that can assess and diagnose problems without the need for human interaction are all benefits of this integration.

In the manufacturing industry, Industry 4.0 solutions are based on maximum automation of all activities performed during the production process. Industry 4.0 technologies are advanced production management systems such as MES, WMS, EMS or ERP. Industry 4.0 requires less human labor, while the supervision of operations can be carried out regardless of the physical distance from the production hall.

Industrial Revolution 4.0 also means the possibility of full remote control of the production process from anywhere in the world. The Industrial Internet of Things makes it possible to introduce changes, generate reports and, on their basis, conduct analysis of the manufacturing process, as well as changes in the production itself on the fly.

Availability = actual machine running time / scheduled time

Productivity (actual production time / production capacity)

Quality (number of pieces properly produced / total production)

In the manufacturing industry, emphasis is placed on achieving optimum performance in all three areas, which is key to successful line operation as each area individually contributes to the profitability of a product or service and profitability.

OEE can also be represented as actual production divided in the denominator into scheduled time multiplied by one production cycle, as shown in the formula below:

Ultimately, OEE is influenced by many factors that depend on the overall operation of the factory. Among the events that have an impact are

1. Unplanned downtime
2. Failures and repair times MTTR, MTBR, MTTF
3. Slow start-up of production
4. Late recognition that a process is unstable
   

Read more about OEE in the article “12 reasons why OEE is low”.

Calculate your OEE in no time with our OEE calculator.

A Manufacturing Execute System (MES) is an independently functioning software that allows to collect operational data from a production line and to visualize it in a clear and understandable way in order to make faster decisions based on real data. It supports plant operator in daily tasks and enables data input if automatic data collection is not available.

MES software through the ability to collect and clearly present information in the form of tables, graphs and charts, supports the implementation of lean management and lean planning and continuous improvement methodologies in the manufacturing plant.   

The main factor in manufacturing companies affecting the quality of information presented by MES class systems is the source of data. Two main ways of supplying the system with data can be distinguished:  

• Machine connectivity – allows for automation of data collection and minimisation of manual reporting  
• Manual data entry by an operator  

Another possibility of supplementing data in the MES system is the integration with ERP systems. Most often, the integration allows for two-way data flow, so that both the ERP and MES systems have uniform data on the ongoing production.   

Read how to audit your factory to implement software system

MES System Benefits

1. Real-Time Data Collection: Provides immediate access to production data for faster decision-making.
2. Improved Efficiency: Streamlines operations and reduces downtime with automated data collection.
3. Enhanced Quality Control: Monitors production processes closely to ensure high product quality.
4. Better Resource Management: Optimises the use of materials, labour, and equipment.
5. Traceability: Tracks the entire production process, improving traceability and compliance.
6. Reduced Costs: Minimises waste and rework, leading to cost savings.
7. Integration with ERP: Ensures seamless data flow between MES and ERP systems for unified information management.

MES as the Control Tower

Imagine a Manufacturing Execution System (MES) as the control tower at an airport. The control tower doesn’t fly the planes but is essential for ensuring that all flights take off, fly, and land safely and efficiently.

The MES (or control tower) gathers data from various aircraft (machines on the production line) and visualises this information in a clear and understandable way, much like how air traffic controllers read radar screens and flight data. This helps the controllers make real-time decisions to keep the air traffic flowing smoothly.

Read more about MES System

• MES – Manufacturing Execution System – MES Software Page
• OEE – OEE Performance monitoring – Simple MES System
• MOM – Manufacturing Operations Managements System – The most advanced MES System

Where MES System brings benefits, list of industries:

• Consumer Goods
• Aviation & Areospace
• Pharmaceutical
• Automotive
• Military
• Assembly

ERP system can be used by planning, purchasing, sales, marketing, finance, human resources, warehouse and other departments where integration of data within the enterprise can bring tangible benefits.  

Today ERP systems are very diverse and often specialized for a specific industry, so that they can best reflect the specifics of a particular sector of the economy. Over time, systems have evolved from desktop systems to cloud solutions, enriching the usability and flexibility of solutions.  

Technological changes taking place in the manufacturing industry and the complexity of current manufacturing processes, make it necessary to extend ERP systems with additional functions. Additional tools include independent MES, WMS, LIMS, or EMS systems, which allow two-way data exchange with the ERP system, providing more accurate information about the production process and plant status.     

Despite the many benefits of implementing an ERP system in the company, poorly planned implementation resulting from the lack of cultural and structural changes in the organization, may prove counterproductive for the entire enterprise.    

Implementing APS software is often a company’s response to the lack of synchronization between departments and processes within the company, in order to bring about full optimization of work. In particular, APS allows to:

• Predicting customer orders
• Anticipation of supply capabilities
• Plan production scenarios
• Eliminate unnecessary excess inventory

An independent and complementary tool to APS is the RTS (Real-time scheduling) solution. RTS is a tool that has all the necessary functions known from APS, but it is devoid of typical ERP functions. It is designed for companies that still want to benefit from intelligent, data-driven scheduling, but do not have full knowledge of real-time production. RTS allows for simplified production planning, taking into account all current available data from the machines.