Online Loss Capturing / MES

A manufacturing execution system (MES) is an information system that connects, monitors and controls complex manufacturing systems and data flows on the factory floor. The main goal of an MES is to ensure effective execution of the manufacturing operations and improve production output.

An MES helps achieve that goal by tracking and gathering accurate, real-time data about the complete production lifecycle, beginning with order release until the product delivery stage for finished goods.

The MES collects data about product genealogy, performance, traceability, material management and work in progress (WIP) and other plant activities as they occur. This data, in turn, allows decision-makers to understand the current settings of the factory floor and better optimize the production process.

Online Loss Report

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Various losses occurring in a manufacturing plant have direct bearing on reduced productivity and increased costs. Though some losses like asset failure can be measured using traditional methods, advance systems are required for root cause analysis. Then there are many miniscule losses which are very difficult to measure. Their frequency of occurrence can be high and hence their cumulative effect significant. These are referred to as ‘minor stoppages’. Yet other types of losses occur due to lack of coordination between various departments. This case study demonstrates how PlantConnect SFactory, a Smart Factory solution from Ascent Intellimation tracks and analyzes all types of losses and helps in eliminating some losses and reducing others. The installation is done in. Overall business requirements of customer are:

• Loss analysis
• OEE improvement
• Just-In-Time Maintenance

THE SOLUTION PlantConnect SFactory with integrated Loss Analysis Module was deployed. Losses are categorized as:

• availability losses
• performance losses
• quality losses

A 3-level hierarchy is created for losses Loss Area (A / P / Q)
• Loss category
• Loss reason