ANT Smart Factory complete industry 4.0 solution for modern factory

ANT SMART FACTORY

ANT Smart Factory is a software system that includes 7 products and over 1250 features to support all activities in the manufacturing plant.

The main benefits are that production is running faster, more efficiently with higher quality.

The system manages processes in production, maintenance, planning, quality, technology, operations, and logistics departments.

The solution provides a scalable platform, which means that the system can grow from a single work center or line to hundreds of them in many sites.

The selection of the right modules and its customization brings the best-fitted solution for Client requirements.

We believe in transparency that gives unlimited user access to share information across the company.

This data is used for scheduling, production execution with operators’ guidance, condition-based monitoring, preventive maintenance, quality inspections, and analysis based on real-time data acquisition from machines.

SELECT FROM ANT SMART FACTORY product-energy-monitoring product-warehouse-management product-mes product-mes-2 product-real-time-scheduling product-maintenance-management product-interactive-plant product-advanced-productivity-management product-advanced-productivity-management-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

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

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

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

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

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

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

Solutions proven by
the top companies

Macbook

MES

All-in-one solution to production processes monitoring.

MES System provides machine data collection and paperless production execution.

Production progress feedback in real-time with digital step by step instructions and documentation guides operators through the manufacturing process in order to maximize production efficiency.

The solution enables changeovers reporting, defect handling, traceability, quality inspections, OEE & KPIs calculation with analysis dashboards and bi-directional ERP integration.

 

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

Bi-directional machine communication enable detailed machine signals data acquisition with micro-stoppages monitoring. System records downtimes at equipment level and automatically assigns reasons. It allows identifying bottlenecks, observing stock buffers and finds root causes to maximize machine loading and minimize downtimes.

Thorough track&trace records hundreds of process parameters helps with structured problem solving.

Changeover production faster thanks to automatically recipes sending and machines set-up on-the-fly.

 

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

Software for production plan optimization with advanced algorithms that chooses the best planning sequence to ensure on-time delivery, resource usage, machines&tools capacity and priority.

The system tracks production performance for each item, adopts a plan to reality and monitors its online progress. The planning tool is learning itself based on historical reports and real-time data collected from machines. It allows for long and short term production scheduling.

Graphical plan visualization with drag&drop capabilities on Gantt charts leads to ergonomic and user-friendly way of scheduling.

 

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 LATE SHIPMENT DATE
  • MINIMIZING COST (CHANGEOVERS, RESOURCES)
  • RESPECTING PRIORITIES

HISTORY LEARNING

  • REAL PRODUCTION EFFECTIVNESS
  • AUTO RECALCULATION OF REAL CYCLE TIME

maintenance scheduling

  • DIGITAL COMMUNICATION BETWEEN DEPARTMENTS
  • AUTOMATIC WORK ORDERS PLANNING
  • WARNINGS

Maintenance management

CMMS allows to plan, execute and analyse maintenance works in the plant. The system automatically plans recurring inspection based on cycles and work time collected from machines and tools. Every maintenance task is scheduled based on available resources and production plan.

All maintenance actions are registered in real-time on mobile application including task status reporting, time monitoring and usage of spare parts. By using preventive and predictive maintenance based on sensors and history leads to reduction of failures.

Platform comes with an analytics dashboard with detailed costs for each asset, planned activities, machines log book and TPM KPI’s like MTBF, MTTR.

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 plant

Software dedicated to support shift and operating meetings by Digital Visual Boards. It allows to design own Meeting Board templates using drag&drop and pre-configured modules to build dashboards in easy way. Touch screens are used at every meeting for production results review and to generate tasks on Action Board. Workflow managements helps to track each step of acceptance in documentation flow to keep organization more effective.

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 INTERFACES
  • DOCUMENTATION FLOW EXECUTION
  • DOCUMENTATION MANAGEMENT

Warehouse Management

Link between warehouse and production which provides data about stock volume and its movements.

WMS monitors inventory on warehouse and production WIP (Work In Progress) to visualize current material demand.

System guards to deliver components on time without production stops by displaying logistic delivery sequence on wide screens and monitoring its actual progress.

Mobile devices are used to record warehouse transaction by scanning labels on logistic units, warehouse locations and items.

System supports palletization and pickup process to guide operator step by step with FIFO or LIFO policies.

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 PLANNING AND VALIDATION
  • SHORTAGE REPORT
  • SALES ORDERS MANAGEMENT

wms mobile

  • WMS MOBILE APPS
  • QR CODES SCANNING
  • NFC TAGs SUPPORT
  • LOCATION OR LOGISTIC UNIT STATUS
  • PHOTOS UPLOAD
Warehouse Management

energy monitoring

Energy Monitoring System provides media consumption management in a production plant.

By connecting to measuring devices, the solution collects data about electricity, gas, water, compressed air, heating, cooling, steam, temperature, humidity consumption.

Thanks to synchronizing energy usage data with ANT MES, the system calculates the real production cost for each item.

Power Guard monitors and predicts energy consumption and notify about any deviations.

 

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