ANT Smart Factory System for Manufacturing Operations Management

Production
under control

Run your production more efficiently using dedicated modules for production, quality, maintenance, production planning, and process engineering

 

ANT Smart Factory brings benefits for the production environment

 

The system allows to achieve:

 

– accurate and fast production reporting

– real data from machines to analyze

– paper reduction and all digitized

– faster production launch

– waste reduction

– traceability with material validation

– automatic quality measurements

SELECT FROM ANT SMART FACTORY product-7 product-6 product-1 product-1-2 product-3 product-4 product-5 product-2 product-2-2

SELECT FROM ANT SMART FACTORY

Monitor production processes and follow its efficiency in real-time thanks to machine data collection with operator’s assistance to smart execute production read more…

Maximize machine performance with automatical micro-stop, bottlenecks identification and reduce changeover time to 0 by automatized setup read more…

Use advanced algorithms to optimize production plan and create a realistic schedule based on history learning to deliver products on-time read more…

Minimize assets failures and downtimes thanks to preventive maintenance with condition-based monitoring and cost control read more…

Faster shift meetings using touch screens with auto-generated reports from production. Monitor planned actions progress and use digitalized documentation workflow read more…

Ensure production continuity by delivering materials just in time to the shop floor based on online demand from ANT MES system read more…

Control energy costs used to produce each product and prevent exceeding the contract limits read more…

ANT MES

A First-Class Manufacturing Execution System for high-volume production

Our customers used to say – “Efficient Manufacturing Every Shift”.

We achieve a double-digit performance increase due to the three key assumptions:

REAL PRODUCTION DATA

There is no machine that cannot be connected!
Real data from both the newest and the oldest machines, collected via standard and custom protocols are mandatory.

INVOLVED OPERATORS

Operator interface – panel, tablet, terminal or smartphone – always clear, easy to use, fast and friendly. The operators are supported by a tailored set of functions to ensure the work is highly efficient.

EMPOWERED MANAGERS

Managers log in to the system using a browser to access dashboards and reports. They start by reviewing KPIs and then go into details.
Drill down. The system assists managers by highlighting the data that is most worth seeing because of its impact on overall efficiency, e.g. TOP 10 failures, wastage, discards, speed losses, switching times, etc.

MACHINE DATA ACQUISITION

  • • Standard Protocols
  • • Custom Protocols
  • • Dedicated Machine Solutions
  • • Iot/ Edge Architecture Option
  • • Basic Machine Dataset

 

Production execution

  • • Orders Starting And Execution
  • • Production Progress Monitoring
  • • Operator Basic Panel
  • • Machine States Handling
  • • Reject Handling

 

OPERATOR ASSISTANCE

  • • Operator Performance Feedback: OEE
  • • List To-Do Activities (Paperless)
  • • Operator Guide
  • • Real-Time Notifications, Advice And Tips
  • • Work-In-Progress Monitoring

 

SYSTEM INTEGRATION

  • • Inbound Erp Interface
  • • Outbound Erp Interface
  • • Bi Interface
  • • Access Control System Integration
  • • 3rd Parties Systems Interface
  • • Safe Data Export To Cloud

 

MASTER DATA MANAGEMENT

  • • Items And Materials
  • • Bom
  • • Routings
  • • Recipes
  • • Machines And Equipment
  • • Employees
  • • Defects
  • • Labelling
  • • Teams Management
  • • Versions Management
  • • Quality Management
  • • Orders Management
  • • Activities Management
  • • System Management

OEE & KPIs MONITORING

  • • Reports Flexibility
  • • Performance General KPIs
  • • Maintenance KPIs
  • • Quality KPIs
  • • General Cost KPIs

MANAGERS DASHBOARDS

  • • KPIs Cockpits
  • • Breakdowns
  • • Changeovers
  • • Machines And Lines Activities
  • • Benchmarks Top10
  • • Employee
  • • Trend Chart
  • • Custom Reports

SHOP FLOOR VISUALIZATION

  • • Shop Floor Dashboards For Large Screens
  • • On-Line Production Performance Visualization
  • • Andon Notifications

 

TRACEABILITY

  • • Electronic Batch Record
  • • Track And Trace
  • • Material And Components Traceability
  • • Material Validation, Product Qualification
  • • Full Product Genealogy
  • • Traceability Report
  • • Serialization & Labelling
  • • Audit Trail

 

ANDON

  • • Maintenance Call Andon
  • • Quality Call Andon
  • • Logistics Call Andon
  • • Notifications Via Sms Or Mobile App
  • • Dispatching Andon Orders
  • • Andon Escalations
  • • Andon Reporting
  • • Andon Mobile

 

QUALITY

  • • Shop Floor Inspections
  • • Material Parameters Checks
  • • Advanced Defects Reporting
  • • Product Acceptance
  • • Quality Checks Notifications
  • • Quality Plans
  • • SPC
  • • Sample Testing
  • • Reworks
  • • Advanced Quality Reports

 

ADVANCED PRODUCTIVITY MANAGEMENT

ADVANCED PRODUCTIVITY MANAGEMENT

Boost your company’s production capacity without investing in new machinery, halls or salaries. Increase your margin with three smart functions:

STOP the STOPS

Detect the real reasons for breakdowns. Find out which machine is responsible for failures, delays, rejections and why. Instant notifications help operators reduce current losses. Analyzes, like OEE loss tree, Pareto or fishbone diagrams help managers prevent stops.

PREDICTABLE MAINTENANCE

Prevent failures even while reducing routine maintenance, due to Condition-Based Maintenance, fed by hundreds of measurements collected from PLCs, sensors, cameras.

MACHINE SETTINGS ON THE FLY

Along with the new production order, the recipe is sent to the machine. Reduce the changeover time to ZERO.

ADVANCED MACHINE DATA ACQUISITION

  • • Bi-Directional Machine Communication
  • • Advanced Machine Dataset
  • • Recipes Import/Export
  • • Operator Activities, Settings And Logs (Audit Trail)

 

MICROSTOPS ROOT CAUSES

  • • Automatic Downtime And Root Cause Reason Detection
  • • Structured Problem Solving
  • • Drill Down Analysis

 

MACHINE AUTOMATIC SETUP

  • • PLC Setpoints Upload On The Fly
  • • Automatic Changeovers: Recipes Upload And Selection On The Fly
  • • Process Parameters Real-Time Adjustment

 

MACHINE SETPOINTS

  • • Manual and Automatic Setpoints Templates
  • • Continuous Check of Machine Setpoint
  • • Manual Check Notifications and Confirmations
  • • Proactive Behavior

 

MACHINE STATISTICS

  • • Line Bottleneck
  • • Cycles Time
  • • Buffering Time
  • • Rejects Reasons

 

real-time scheduling

real-time scheduling

The standard planning is not enough, that’s why our customers choose ANT RTS. They do it regardless of whether they already use APS or plan production in ERP. Here are the key reasons:

REAL PLAN

The RTS calculates the actual time of the order execution according to history, so the plan is realistic. What was planned, is simply done.

REAL-TIME CONTROL

The production plan is updated in every cycle and you control simply its execution.

ALL-IN-ONE

Production orders, changeovers, maintenance – all-in-one schedule. Thanks to this all dependencies and resources are visible. This enables effective management and adjustment of the plan to the current situation.

Production scheduling

  • • Online Production Progress Update
  • • Alternative Planning Scenarios
  • • Plans Comparison
  • • Detail Scheduling
  • • Changeovers Matrix
  • • Employee Matrix
  • • Drag&Drop Gantt Chart

 

OPTIMIZATION ALGORITHMS

  • • Multidimensional Optimization
  • • Maximizing Shipment Date
  • • Minimizing Cost (Changeovers, Resources)
  • • Respecting Priorities

 

HISTORY LEARNING

  • • Real Production Effectiveness
  • • Auto Recalculation of Real Cycle Time

 

maintenance scheduling

  • • Digital Communication Between Departments
  • • Automatic Work Orders Planning
  • • Warnings

 

CMMS

Production efficiency depends on the availability of machines. Ideally, when production and maintenance use one system. This is the first of three key reasons for choosing the ANT CMMS system:

PRODUCTION AND MAINTENANCE IN ONE SYSTEM

Plan production and maintenance together. Receive the ANDON notifications sent by machine operators. The better collaboration the higher MTBF.

MOBILE SOLUTION

Use modern technologies, like smartphones, tablets, mobile terminals, NFC tags. Increase technicians’ engagement. More and more companies are choosing mobile solutions. Our system is ready for it!

BASED ON REAL MACHINE DATA

Enable the Condition Based Maintenance! Preventive maintenance is performed according to the actual machine’s condition. This results in fewer breakdowns while reducing routine maintenance.

CMMS

  • • Equipment And Objects Management
  • • Orders Management
  • • Maintenance Notifications
  • • Work Scheduling And Assignment
  • • Condition-Based Monitoring
  • • Preventive Maintenance
  • • Predictive Maintenance
  • • Corrective Action
  • • Spare Parts Management
  • • Reports

 

CMMS & ANDON mobile

  • • CMMS Mobile Apps
  • • Andon Mobile Apps
  • • QR Codes Scanning
  • • Photos Upload

 

tool shoop

  • • Tool Cycle Limit Monitor
  • • Monitor Life Cycle Of Sets
  • • Sets Identification
  • • Regeneration
  • • Cycles Number Monitoring
  • • Managing Sets

 

Interactive meetings

People make the factory. The better communication tools they have, the better they work. Look into the three following cases:

EFFICIENT MEETINGS

Discuss the data on-line, finish on time, save the arrangements and go. Start the next meeting by checking the results from the previous one. This is an interactive meeting.

CLEAR MESSAGE

Show employees their results and goals clearly. Indicate what is important, what requires attention. Motivate people. Use the visualization that will be noticed, remembered and arouse good emotions.

PAPERWORK UNDER CONTROL

Track the document flow performance to speed up the process and make it manageable. It’ll be easy to check the status of the selected document and change its order, to release the product to the customer ASAP.

INTERACTIVE MEETINGS

  • • Meeting Template Creation
  • • Agenda Creation
  • • Meeting Conduction

 

workflows

  • • Workflow Template Creation
  • • Data Interfaces
  • • Workflow Execution
  • • Workflow Entities Management

 

PRODUCTION DOCUMENTATION FLOW

  • • Documentation flow template creation
  • • Data Interface
  • • Documentation flow execution
  • • Documentation management

Warehouse Management

Warehouse operations must be as efficient as the production itself. Therefore, the solutions adopted from production are used in the warehouses. It gives at least three key effects:

EFFICIENT RECEIVING

Allocate the appropriate number of employees to receive the goods in order demanded by production. No more downtime due to a lack of components.

SHIPPING ON TIME

Control the order execution and the on-time shipment readiness. The shop floor’ visualization shows what is ready to be loaded and what is still missing. No more delays to customers.

THE RIGHT COMPONENTS

Track a batch of components from delivery to shipment of the product. Make sure you use the correct parts with known serial numbers.

WMS

  • • Inventory Management And Master Data
  • • Warehouse Overview
  • • Goods Receiving
  • • Goods Dispatching
  • • Stock Transfer
  • • Return Transfer
  • • Palletizing
  • • Inventory
  • • Special Processes
  • • Material Demands
  • • Logistic Cockpit
  • • Hot-Items Notification
  • • WMS KPIs Reporting

 

SHIPMENT PLANNER

  • • Shippment plannnig and validation
  • • Shortage Report
  • • Sales orders management

wms mobile

  • • Shipment Planning and Validation
  • • Shortage Report
  • • Sales Orders Management

 

Warehouse Management

Energy Monitoring System

Energy drives your factory. Make sure that the bills are not overpaid, your equipment will not stop suddenly and there are no leakages that may be sealed easily.

Look into the next three benefits:

LOWER PRODUCT COSTS

Analyse your energy efficiency calculating the amount of energy consumed per product, process, machine, department. For productive and non-productive purposes. According to ISO 50001.

LOSSES ELIMINATION

Control and prevent losses in the transformers, compressed air distribution, in heating, cooling, and lighting. You will be notified when an overrun is detected. System can also switch off selected circuits to eliminate further losses.

DAMAGE PREVENTION

Control the temperature of devices, a load of busbars and cables. Monitor the power equipment to prevent production stops.

METERS DATA ACQUISITION

  • • Electricity
  • • Gas
  • • Water
  • • Compressed Air
  • • Heating
  • • Cooling
  • • Steam
  • • Temperature
  • • Humidity
  • • BMS Monitoring And Control

 

ENERGY SUPPLY PARAMETER

  • • Main Counters Details
  • • Standard Protocols
  • • Diagnostic
  • • Notifications

 

POWER GUARD

  • • Billing Counters

DISTRIBUTION AND TRANSFORMING LOSSES

  • • Distribution of Media

ENERGY CONSUMPTION ALLOCATION

  • • Consumption Analysis
  • • Per Area, Line, Machine, Product
  • • ISO 50001

 

GREEN FACTORY ENVIRONMENT FOOTPRINT

  • • Automatic Calculation of Production Impact on the Environment
    • Manual Entry of Activities Influencing Increase of the Co2 Emission
    • Analysis of Factory’s Overall Impact on the Environment

ENERGY DASHBOARDS

  • • Analysis From Top to Bottom
  • • Energy Type Choice
  • • Area Selection