COMES-obrazovky-uvodni Many companies have installed modern technology equipped with a high level of automation, more or less effective IT systems and have optimized their logistical and control processes. Is there anything else that could help companies improve their production efficiency?

The analyses and studies of production processes of specific companies show that there is. Many companies can further improve the operative control of production by linking the individual control levels effectively, whether this concerns organizational or installed systems. How to achieve such effects?

Electronically Controlled Production

Electronically Contolled Production is a proved concept and modern solution for operative control of production. It supports a high and equal production quality, increase of productivity and minimum production costs. Electronically Controlled Production is a solution that supports the production team to achieve the best results

The solution by COMPAS automation provides the production team with the required information in an electronic form in real time. Our solution is based on the integration of corporate systems ERP – MES – automation. The COMPAS solution saves administrative activities both to production operators and managers who can use the information from the production, such as technology status, production quality, information about materials in progress or performance indicators and line capacity utilization (OEE). The greatest benefits are the minimization of production costs, boost of efficiency and improved quality of production.

Standard Manufacturing Execution Functions (MES)

Electronically Controlled Production integrates the following areas of operative production control:

  • Detailed production scheduling (weekly, daily and by shifts)
  • Personal management
  • Material management, material labelling, production logistics, traceability, warehouse management (WMS)
  • Production recipe (procedure, formula) and its parameters,
  • Production supervision and control including direct communication with technology automation systems
  • Quality assurance, material test planning, recording and evaluating, reports and statistics
  • Electronic production records and reports
  • Technological values acquisition, analysis and archiving, control system alarms archiving and filtering
  • Production data collection and archiving
  • Calculation of Key Production Indicators and statistics (KPI, performance, downtimes, OEE…)
  • Computerized Maintenance Management Software (CMMS, EAM)

All the above mentioned functions are well known but it is their linked implementation in the Electronically Controled Production that brings the described effects of truly optimum production control. The following examples from practice show problems arising from the missing system integration:

  • Production planning is often implemented at the ERP level which usually works in an open loop control. Electronically Controlled Production besides, can collect data about products in real time, in addition to the calculation of the optimal production setup and planning appropriate resources, and shows the current production order fulfilment versus the plan in the real time to the operator in the production, the foreman and the production manager.
  • Production team usually knows his plan to shift, but it is difficult to estimate during the shift proceeding whether the operator meets his plan or not. Providing production team with relation "plan versus production results" in real time motivates them to reach their shift targets.
  • Another example is material dosing for batch processes. The ERP system can send information to the operators to manually add small-volume material into the technology but, without relation to the control systems, it cannot control automated dosing of large-volume materials.
  • Production traceability can be solved using manual records or scanning material barcodes in the ERP system, but in most cases the results do not correspond with the needs. Manual records on the material route through the production can only be reliable in small production because in medium-size food or mechanical production material moves every few seconds on average.

Many of the practical examples show that companies may obtain improved results in productivity and intensity of the utilization of working hours, shorter line adjustments between the individual production orders, shorter repairs or reduced production losses. All of that by suitable stuff motivation based on objectively and reliably received information.

Benefits of Electronically Controlled Production

Electronically Controlled Production is an efficient solution that helps you achieve optimum control over your production, even in case of complicated series/batch production. It allows you to effectively plan production, to control and optimize production quality, productivity and costs by providing accurate information in real time. Thanks to providing production team with information, tasks can be distributed effectively to people, including direct control and production process evaluation.