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Manufacturing Execution System (MES)

Extends the Digitalization process

Automatically get data from machines, monitor production and its progress in real-time and have the shopfloor under control. Automate production validation, guide operators through processes and ensure that all operations are done in proper sequence and on time. Make your traceability digitised and automated, improve quality plans to be executed faster, in an automatic way making sure the process is stable. Describe your production process in more detail, besides basic data in the ERP system, to which we do full integration.

Traceability Scan materials and components, theirs S/N and batches and match it to ongoing production. The automated validation will verify if they can be used in production.
Build traceability upstream and downstream.
Quality inspections Gather data for SPC check and for control charts to validate the stability of the process. Gather measurement automatically from devices or manually from operators in periodical, planned intervals. Ensure that quality parameters are within tolerances and limits.
Activities Guide operator through the production process as a step-by-step instruction enriched with image, movie of the document. Make sure your production process is standardized.
Automated validations Check the history of the product and decide if it can go into the production process.
Ensure that all your shipments have fully finished goods and that none of the operations,
activity or quality action is missing.
Reworks & scrap Get a process and routing for reported reworks. Automatically set a reject as a scrap based on the reported defect type. Identify and monitor costs of rejected production.

    Production Under Control with Modern MES

    MES is a comprehensive OEE Performance Monitoring system with Traceability, Quality inspections and Rework management.

    Modern Manufacturing Execution System (MES) covers scanning components and materials used for production.

    While scanning S/N and batches, the system validates and creates a complete genealogy of the finished good.

    The quality module allows creating a quality plan and automatically gathers process parameters from the automation level or manually from operators, including measurements and checklists.

    Periodical data gathering helps in fast check for process stability.

    The rework module allows track and send the defective item to the suitable machine and follow new routing.

    Machine Connectivity​

    Any machine, all protocols

    We always find a way to read data from machines – PLCs, sensors, cameras. The system has built-in communication protocols ready to exchange data with Siemens, Beckhoff, B&R, Allen Bradley or any others. You then get real-time production counters, process parameters like speed, pressure, angle, temperature or other.

    Check dedicated website
    machine connectivity
    production execution

    Production execution

    Monitor and guide​

    When operator logs into the system with RFID card, the system displays the newest production plan in the proper sequence. Operator start production and the system monitors its progress, targets realization and measure cycle times – it all happens on the Operator Panel that is dedicated for each machine or line.

    Defect handling​

    To reduce waste, you need to measure it

    Gather all data from the machines and operators – how many defects, what type of defect, is it a scrap, rework or reject? On what component did it happen? Build full Pareto chart to have data for LEAN actions. The operator can point on the item’s picture where was the defective area and then build a heat map.

    Check dedicated website
    defect handling
    oee analysis

    OEE Analysis​

    What is the trend?​

    Let’s say that you have your OEE – it is automated automatically based on the machine’s data, you have the same equation for all machines and lines so you can compare them. Now it is needed to understand where and why did you lose Availability, Performance and Quality. This is where our OEE Waterfall will help you together with visible trends over time.

    Check dedicated website

    Digital Documentation​

    Forget about paper​

    The operators on the shopfloor shall forget about paper and start using Operator Panels – there are all documents they need for production, changeovers, quality, maintenance or safety. Stop wasting paper and go digital. Documentation is always up-to-date and always available – the access is faster, more user-friendly and cost-saving.

    digital documentation 1
    online visualization

    Online Visualization​

    You look and you already know…

    You walk on the production, you take a glance at the screen on the factory’s wall and you already know which machine needs your assistance and help. In real-time, you can take action, make a decision and save ongoing production to be on time with the order.

    Dashboard & Reports​

    Reports automation in factory​

    We deliver the package of best in class reports and dashboards that were designed during hundreds of projects in top manufacturing companies. You can be sure that your questions about the production have answers in our industrial software. The reports are generated automatically and in real-time.

    dashboards reports
    master data

    Master Data​

    Your processes are unique

    ANT Smart Factory system is flexible and it must be possible to model any production process in detail in the MES system. What is available we read from the external system not to allow any double-work and the rest of technology is configured in our industrial system.

    Maintenance ANDON​

    Fast reaction is crucial

    The system sends notifications about the failure based on signals from the machine or operator. Messages reach technicians to ensure fast reaction and information propagation in the maintenance department. With all knowledge about history issues and available documentation, the system helps to find the right information quickly.

    maintenance andon
    system integration

    System Integration

    Not only ERP system​

    You operate in many systems. Our goal is to unify systems so you could focus on one system and be sure that the information you are looking for is in ANT Smart Factory. The exchange between production systems and others is important like warehouse stocks (WMS), progress update in production plan (APS), dispatching robots (AGV, AMR) and many, many more

    Traceability​

    How is it made?​

    Record all data for further analysis and tracking. Collect data about used batches of components, used tools ID, operators, times and dates, all process parameters and external operations. Everything to maintain control over production and provide full track & trace for your Clients.

    Check dedicated website
    traceability 1
    reworks management

    Reworks Management​

    Do you measure it?

    Reworks can be difficult and take much time to manage. We see a way to optimize it and make this process automatic. Based on the defect type, we set new routing and do the slots for rework production to make processes more effective.

    Quality Inspections​

    Gamechanger!​

    Set proper quality plan to be executed automatically – either automatically based on data from machines or manually by operators. Every 1 hour, after every 60 pieces or any other trigger, ask production to do samples measurement and provide instant feedback if the results meet criteria and tolerances. You can involve the laboratory in this process as well…

    quality inspections

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    Related articles

    Manufacturing execution system – is your company ready for the industrial revolution?

    It is now difficult to imagine a modern factory without a manufacturing execution system. MES manufacturing execution system is a must-have investment if you want to produce more with the same machine park. Competitive factories that operate according to the Industry 4.0 concept have long ago implemented advanced manufacturing execution systems, taking their manufacturing processes to a completely different dimension. Is your company ready for global expansion?

    Manufacturing execution systems – what are they?

    MES system is advanced software used to measure and improve the quality, availability and productivity of production lines. The full functionality of the system depends on the class of the implemented solution. Our MES tracks the actual working time of machines and records downtime by automated data acquiring.. It allows to plan production activities and control their implementation. The system collects information on the quality of manufactured elements. It immediately notifies of any irregularities. Most importantly, it significantly reduces the possibility of wasting resources. It makes production more efficient and profitable.

    MES software guides the manufacturing process through all its stages: planning, scheduling, monitoring, supervision, execution, and optimisation.

    At each of these stages, the manufacturing execution system checks the work in progress – the MES application collects, gathers and processes data, and generates reports. An advanced algorithm analyzes the causes of micro-stops and shows Pareto charts to analyze root causes of current performance levels.

    How does the manufacturing execution system work?

    An advanced manufacturing execution system is connected to the company’s internal system network. Real-time data collection is a huge benefit of the system. It collects data from machines via PLC, sensors installed in all the machines and anywhere on the production line or directly from machine automation. Signals reach it in the form of telegrams, which are short messages informing about the current position and the process being carried out.

    Before this can happen, however, the manufacturing execution system software must be provided with a database of the exact parameters of all components and processes used in the manufacturing process. Where does the MES system get this information from? ERP, that is the enterprise resource planning system, provides the information to your software. However, you must remember to firstly carry out the integration of both platforms. It is possible thanks to the two-way communication of MES and ERP systems. Some information is download from the ERP, and then the whole is refilling with the data created in MES. Information exchange between the systems allows for complete data necessary for an effective completed production plan.

    The MES software continuously checks the quantity of factors needed to complete the production, and if we predetermine a critical minimum level, the software sends a message indicating that new components need to be delivered. Thus, the manufacturing execution system not only operates in real-time but also anticipates possible risks and prevents them effectively. If this is not possible, it immediately sends an error warning message to the operator. MES also reduces the number of micro-stops and shortens the time needed for machine changeovers. Special modules facilitate the tracking of all connected devices and control of plan execution. The software records all downtimes, including micro-stops, which have an impact on the flow of production. Reworks Management is an optimal solution that automates the reworks process. The quality modules help to check the correctness of the manufactured elements.

    Why do you need to implement a modern manufacturing execution system?

    A state of the art manufacturing execution system is necessary to be able to use the full potential of the company’s resources – both technical and human ones. Using MES guarantees that each step of the process has been performed exactly according to the planned technology. While it is extremely important to prevent faults and micro-stops, it is equally vital to ensure that the capabilities of the workforce are fully utilised. This will also make it possible to detect quality-related defects, as it may turn out that the reason for low productivity is not the failure of machines but inefficient work of operators. If there is a threat of process stability loss, the MES system will notice it immediately. SPC reports continuously generate data on the quality of products. If it decreases, this knowledge allows to react quickly and restore process stability.

    With Traceability tracking and tracing of the finished good, semi-finished goods and raw materials is possible. Ongoing production is being matched with S/N, batches of components and containers. The system validates processes and confirms scanned resources. Labeling process is done automatically in any step of production. With Traceability it is possible to find raw material based on scanned finished good and vice versa – after scanning raw material in which finished goods it was used.

    No more wondering why the manufacturing process slows down at certain stages, and why some of the resulting products are of unsatisfactory quality. The MES software makes it possible for a manager to remotely view the work of all operators at any time.

    How does an MES system change manufacturing operations?

    Industry 4.0 is a concept based on high-level digital industrial technology.

    The faster the industry developed, the more important cross-system integrations became. What matters now is not only what the system can do, but also how it interacts with other software. The manufacturing execution system MES connects seamlessly with other management systems such as WMS, EMS or ERP.

    How does remote quality management affect OEE?

    Manufacturing execution systems are implemented to make manufacturing processes more and more effective. How can we measure their efficiency? MES collects data in real-time and sends notifications enabling quick response. The system sends directions to operators and guides them through the production process. All these steps reduce reaction time and indicate areas for improvement. The implementation of these changes increases the OEE (overall equipment efficiency) indicator. The analysis of current and historical data allows checking the factory’s progress in the short and long term. Additionally, the documentation workflow is digital, thus avoiding double reporting and ensuring immediate communication. In order for a company to truly operate in accordance with the principles of Industry 4.0, and thus achieve the highest performance indicators, it is necessary to use advanced software for remote monitoring of work progress.

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