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Line Overview

All the most important information on a single screen, data on the current and next order, the status of the entire line and its individual components. Information about performance and basic KPIS of the line. Higher transparency and ease of data analysis during production.

Recipe Manager

Manage your recipes with the built-in recipe manager. Manage access, modify, improve and track changes to the recipes. Have full control over machine settings, send recipes quickly and automatically. Reduce changeover time to a minimum.

Traceability

Track and trace all your product throughout entire production process. Full history of the semi-product, baches used in the production of the finish good. All information about the product: operations performed, results, status, measurements, all in one place, available for further analysis and also for resolving customer claims.

SPC – Statistical Process Control

Have full control over the stability of your production processes, thanks to integrated Statistical Process Control analysis. Detect even the smallest deviations and prevent production losses.

Real time OEE

Analyse Key Performance Indicators and Overall Equipment Effectiveness in real time, based on data gathered from PLC. Identify losses with dedicated analytical dashboards, data presented in the form of a  loss tree helps Operator easily understand the data presented and detect potential root causes and then eliminate them to increase line performance.

Rework & scrap

Reduces your losses, due to full real time production monitoring. All scrap and reworks are automatically reported by PLC or Operator during entire production processes. Build-in Decision Point supports Operator in making key decisions during the rework process.

Smart Machine – Out-of-the-box solution for Automated Assembly Lines

Smart Machine is a complete line control system supporting all operations and operators’ activities dedicated for automated assembly lines. System provides automated changeovers on-the-fly together with advanced line control of all WPCs on each station. System ensures uninterrupted operation of the assembly line and timely execution of production and quality. That guarantees the highest OEE as well predictable line’s work, every shift and every day.

System is fully embedded with basic automation. Thanks to standardized and predefined communication can be easy connected with any PLC and any line’s supplier. A standard PLC library with a transparent telegram structure and a user-friendly interface allow a fast and easy integration with the Smart machine.

System is design to ensure smooth operation, configuration, maintenance the line and to support operators in correct problem-solving.

Smart Machine covers special processes like clearing the line, golden (dummy) parts and SPC checks.

Modular architecture of our system, gives unlimited possibilities for free configuration of the system, so that our product can be tailored to any requirements set by our customers.

Smart Machine will help your business in a daily management and production  execution by effectively collecting, visualizing and analyzing data across your entire supply chain.

Machine Connectivity

Gather data and control WPCs

Machine Connectivity is responsible for communication with the machine’s PLC and devices. Thanks to the standardized and predefined communication protocols, telegrams structures can be easily implemented with any PLC. A standard PLC library with a transparent telegram structure and a user-friendly interface allow fast and easy integration with the Smart machine.

Line Control

It’s all about control, crosscheck and validation

The module responsible for controlling and validation of product proceed through the line. Each piece is checked and the system decides where to transfer the product after each operation, validates quality criteria and decides whether a product is OK/NOK based on an analysis of the results obtained from the PLC compared to the set quality limits.

Data Acquisition

Counters, signals, process parameters, states

Having native communication with each machine in the line, ANT Smart Machine is gathering huge amount of data into the system for automated reporting, T&T (Track & Trace), production monitoring and real-time analysis.

Production Execution

Line under control

Production Execution let operators execute orders and operations according to plan and technology. It validates and supports different types of production processes during which the operator can report production and machine states. The system displays current production, its status and progress. Operators can monitor production in real-time.

Operator Guidance

Proceed step by step

The system guides the operator step by step on what to do in the next step, starting from scanning the BOMs, sending recipes to PLCs, starting dummy tests (golden parts) or accepting the newest documentation. Additionally, the instructions for the production or changeover are enriched with images or movies.

Decision Point

Automated reworks management & defects

The system automatically records all defects, place/operation of occurrence and its type reported by PLC or by Operator. With Reworks Management it is possible to create a dedicated production flow based on the type of defect. The new route is saved to the WPC’s RFID chip and the WPC is going to the expected station for rework. ANT’s Master Control logic decides about bypassing unnecessary stations.

Traceability

Full Track & Trace

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. The labelling and marking process is done automatically in any step of production. With Traceability, it is possible to find raw material based on scanned finished goods.

Microstop Monitoring

Automatical bottlenecks detection

The module registers each, even the shortest stop of the individual stations and its reason from PLC. Build-in algorithms assign responsible machines for a line stoppage. It helps to automatically identify bottlenecks and each machines’ status.

Quality Inspections

Automated control and real-time analysis

Built-in set of tools for statistical analysis of the process, such as histogram, control cards and more. Allows detailed analysis of data collected at each stage of production in terms of stability and deviation from planned limits of each production process. The tool allows you to quickly detect even the smallest deviations in the process and react before product quality discrepancies appear.

Production Monitoring

Progress and counters

System monitors constantly the number of OK parts – reported at each station separately, number of NOK parts – reported at different places. Production counters are gathered in real-time giving you information about current production progress, number of products on the line and already produced.

Digital Documentation

Forget about the paper

Digital Documentation let users display documentation online on the operator panel. Categorized PDFs, images and movies are being displayed for ongoing production. The module helps to eliminate paper from the machines and let users for faster access to needed documents.

Online Visualization

Transparent production on TV

Online Visualization displays current production on TVs that are installed on the shop floor. Visualization includes production data with current OEE, production progress and machine states for ongoing production shift. It helps in production transparency and faster reaction times.

Master Data

Configure it by your own

Place in the system where you can model your production process like machines, routings, recipes, production orders any many more. Data can be inserted directly in the system, imported from prepared Excel templates or from any ERP.

Dashboards & Reports

All data in ANT system

Dashboards & Reports is a complex analytic platform with ready reports. More than a dozen reports analyzing production, quality, trends and targets. Reports can be viewed in the perspective of line, machine (station) and in different time ranges.

OEE Analysis

Your OEE equation

OEE Analysis calculation in real-time. The module is responsible for displaying KPI together with availability, performance and quality. Managers are able to set individual OEE calculation methods dedicated for the line. The OEE let users check the current line’s health.

System Integration

Any system!

System integration is responsible for receiving inbound data and for sending outbound data to any other external system. It works in real-time. Different integration ways are supported like web services, intermediate databases or flat files. The module is compatible with any ERP, MES or BI systems.

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    How will smart machines change the future of manufacturing?

    Over the past few decades, industry has evolved at a rapid pace. In many areas, human hands have been replaced by robots, while advanced computer systems perform calculations that humans can only dream of. Artificial intelligence and smart machines are increasingly taking control of the production process. Should we see this as an opportunity or a threat? How are smart machines changing the face of industry? And above all: is there anything to fear?

    What is a smart machine?

    Smart machines learn along with humans. And this is no joke! Advanced systems such as MES, WMS, EMS, and other software that support various industries are responsible for collecting, analysing, and exporting data. Smart machines send information to the aforementioned programmes, enabling process optimisation. They also increase the production capacity of a company.

    This process can be carried out thanks to the sensors installed in devices. Artificial intelligence receives impulses from them and then processes them in real time, evaluating them for available transformations.

    Another function is the automation of operations. Tasks such as starting or shutting down a machine can be performed without the presence of a human. The same goes for updating the production schedule. A smart machine not only implements the previously set parameters, but it is also able to react at the right moment based on the data analysis and change the settings so that the results obtained are as optimal as possible.

    What is smart manufacturing?

    Smart manufacturing means producing components with the highest quality factor at the lowest possible cost. How is this possible? An important component for operational success is repeatability. A human task is always affected by the human factor. With the same semi-finished products and using the same equipment, there is a risk of error that can occur due to fatigue, lack of accuracy, or other human error. Smart machines eliminate this risk.

    Using proven equipment and calculated parameters, we are guaranteed that every component created from a single recipe using the same process will be identical. What is more, a smart machine never gets tired. Most high-tech equipment has a long service life and can work continuously for many hours with the same accuracy.

    If the rate of micro downtime is minimised at the production planning stage, smart manufacturing will provide the company with production that is more efficient by as much as a dozen to several dozen percent!

    Artificial intelligence – how does it work?

    Artificial intelligence ensures that the system is in constant communication with the machine. Messages are displayed in the form of telegrams, which are short and repetitive announcements. Each successive action or movement of a product along the production line has its own label. These messages are sent in real time and are intuitive to read, so you can quickly determine what is happening at a particular stage of production. The telegrams also provide information about a specific activity, such as whether a component has already left its starting point, is moving along the production line or has already arrived at its final destination. If an error occurs along the way, the telegram is the first impulse sent to the system.

    Another example is automatic quality control. Each product undergoes ongoing testing, based on which the system decides whether it can go to the next stage or is classified as waste or a defective product.

    Artificial intelligence and smart machines support the operators. This means that any properly trained person can supervise the machine. The system guides them by sending simple text, voice, or graphic messages.

    Smart machines also have control over production execution. Remote monitoring allows the production schedule to be implemented according to the assumptions set. The system supports the operators by providing regular reports on the current activities. In this way, the production process is monitored in real time, eliminating the possibility of costly errors.

    Smart machines – advantages for your company

    Smart machines take modern businesses to the next level. They make companies more efficient in their processes. Optimisation of operations and minimising costs lead not only to savings but, more importantly, to an uninterrupted supply chain and more opportunities. Spending on artificial intelligence pays for itself quite quickly. The money saved in this way can be used by the company for further investments and the implementation of new solutions.