Post on 13-Jul-2015
Plant Monitoring & Performance Optimization…with the experience of a leader…
The new software generation for the Industry
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Εισαγωγή
Lot’s Tacking
Conclusions
Plant Vision
Quality Control
FSMS
Agenda
Description of the problem
Monitoring and Controlling of the Production
Operations
Total Traceability
Quality Inspection
Food Safety
Conclusions
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Lot’s Tacking
Conclusions
Plant Vision
Quality Control
FSMS
The absence of a system for the production process,
constitutes the inspection and controlling of the production impossible.
The current situation
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Lot’s Tacking
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Plant Vision
Quality Control
FSMS
The Problem – Lacking control of Production Processes
“Many production companies coil from the ERP, which not only failed
to achieve the expected results, but had also negative implication in
the production” (AMRResearch).
“Poor Supervision into plant operations, was the biggest problem for
the Director of the factory” (Forrester’s research, 2000).
“The most efforts to increase the productivity in the factory, suffer
from the same syndrome. The accuracy, the immediacy and the
effectiveness of the production elements” (John Dyck April 25th 2002)
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Lot’s Tacking
Conclusions
Plant Vision
Quality Control
FSMS
The Challenges “Total Traceability”
Fast Response Time
Minimizing inventories of Intermediate Items (WIP)
Immediate recognition and problem solving
Documenting results of quality inspections
Keeping Lot’s genealogy
Analytical tracking of production related elements
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Lot’s Tacking
Conclusions
Plant Vision
Quality Control
FSMS
The Solution “RF technology in Production”
The usage of barcoded production documents and items’ labeling allow immediate collection of actual data of production with the use of RF technology.
The Visualizator and the Events manager support with real time information the managers’ work of controlling.
Lot’s genealogy ensures “up stream” and “down stream”tracking within the plant.
Inspection and Control of Production
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Lot’s Tacking
Conclusions
Plant Vision
Quality Control
FSMS
Basic Principles “Goods Flow Monitoring in Production”
ProductionProduction
MaterialsIntermediate
Materials
Material
Intermediate
Item
ProductionPhase
ProductionPhase
Intermediate
Items
Products
Products
Materials Products
Movement
Issue
Receipt
Cycle Count & Transactions
Inventory Transactions
Intermediate – Semi-finished Item Semi-finished item, Stored in a
production warehouse
Output of a production phase
Item consumed in a production phase
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Functions “Goods Flow Monitoring”
Set-up of production specifications
Creation of production orders – soft allocation
Goods issue
Materials consumption through production
Production of semi-finished and intermediate items
Co-products
Production Delivery to the storage warehouse
Completion and closing of production orders
Movements’ automation
Cycle Counting of Production inventories and reallocation of differences
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Lot’s Tacking
Conclusions
Plant Vision
Quality Control
FSMS
Functions ”Goods Flow Monitoring”
Production
Issue
Production
Receipt
ProductionPhase A
ProductionPhase B
Production
Issue
Production
Receipt
WH
WIP A
WH
WIP B
WH
Raw Materials
WH
Finished Products
Production
Delivery
Production
RPL
RPL
Production Replenishment
Replenishment
Replenishment with total quantities
Replenishment with partial quantities for a range of days
Centralized replenishing
Considering unallocated WIP inventories
Issuing and picking for non-warehouse managed storage locations
Production Issue
Recording of Production Issues
Automated issues based on estimated values
Direct issue to production
FIFO management
Lot Mixing
Intermediate items issues
Production Process
Pre-selection of Lots
Ability to pre-print the pallet labels
Backflushing of Materials
Inverse backflushing of Produced Items
Production of intermediate with internal movement to the next phase
Direct Production Receipt in the receipt location of storage warehouse
Production Delivery
Other Functions
Cycle Counting of production inventories
Re-Allocation of the cycle count differences
Block – unblock inventory
Materials returns
Zero stock count differences
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Plant Vision
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FSMS
One Case ”Goods Flow Monitoring”
Production
Printed document for expected receipts by order or by supplier & date!The System is immediately informed about the receipt quantities.
Materials are available for production !The production area receives the materials needed, based on the specific document !
The system is immediately updated and the stock is still under control
and visualized in the “production warehouse” !
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Plant Vision
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FSMS
One Case ”Goods Flow Monitoring”
Production€€
Material’s issuing is executed based on printed documents !Production is continuously controlled and visualized !
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Lot’s Tacking
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Plant Vision
Quality Control
FSMS
One Case ”Goods Flow Monitoring”
Production€ €€
Low cost materials can be buck-flashed, to minimize the effort !Products are visualized as available for inbound !The warehouse inbound is executed based on printed document of
product’s availability. The system is immediately updated!Similar techniques can be applied on sales deliveries as well !“mobile computing” delivers a flexible way to handle special operations !
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Conclusions
Plant Vision
Quality Control
FSMS
Special Features
Characteristics of the approach
Usage of Production Warehouse to model the Production Area
Usage of Intermediate Items to treat non-finished goods as inventory controlled goods
Usage of Production Phases to record Issue and Receipt
Advantages
Control of Production Inventories like regular Inventories:
Inventory Levels and Inventory Values
Inventory Transactions (Issue, Receipt, Cycle Counting and Inventory Adjustment, Inventory Movement)
Inventory Planning under the aspect of Replenishment
Split of Production Activities into Phases allow the definition of Intermediate Items, that can be traced easily and thereof support the Order tracking.
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Plant Vision
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FSMS
Functions ”Operations Monitoring”
Set-up of BOMs
Production schedule for production orders
Initial entries – completion of the operation
Interruption of the operation and reasons
Recording of non-productive times
Journals for the machines, workers and tools
Management of available resources
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Lot’s Tacking
Conclusions
Plant Vision
Quality Control
FSMS
Visualization - Inventory and Production
The techniques and the diagrams of the Inventory Visualization applied on production areas.
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Plant Vision
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FSMS
Event Manager
Specific parameters constitute reason for event checking, such as negative stock, extend time of delay, work corruption etc.
Each event or the type of the event raises an action from the system, such as an SMS, which is send to one or more receivers, e-mails, messages through RF’s etc.
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FSMS
Elements for the Production Planning
Regarding the Inventory Planning
Calculation of materials quantities, based on the production plan
Availability check of the inventory before the creation of the production order
Current, expected and allocated stocks are considered in the calculation of the available stock
Keeping track of unsuitable stock and stock to be scrapped
Regarding the capacity of the machines
Capacity allocations and utilization in calendars
Secondary production sources are controlled (mould, tools etc.)
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Plant Vision
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FSMS
Cost Elements
The following functions are supported
Standard cost calculation
Estimated production costing and
Actual production costing
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Conclusions
Plant Vision
Quality Control
FSMS
Traceability
Tracing & Genealogy
Lots
Items
Orders
Tracking
Lots
Orders
Transport Bin
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Conclusions
Plant Vision
Quality Control
FSMS
Lots’ Genealogy
Quality Management
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Plant Vision
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FSMS
Quality Inspection Functions
Quality Plans Definition of Quality Inspections by production phase, operation, material
or product
Sampling policy and frequency of measurements
Inspection characteristics, methods of measure, nominal values and tolerances
Tools’ calibration
Quality Inspection Documentation Printing of quality inspection notes
Recording of the measurements
Compliance reports
Technical RF Functions Notes with printed bar code
Entry of the measurement by scanning the note
Food Safety Management
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Conclusions
Plant Vision
Quality Control
FSMS
The Problem…
In European Union we face 7,500,000 to 105,000,000 food poisonings from microbiological sources every year.
The cost for the economy of the EU countries is
8,3 billion €
The cost for the consumers and the medicare system is
UK 1.139.264.119 £ for salmonella in 1996
UK 221.932.358 £ for salmonella for the industry in 1996
In Greece 19,6 billion yearly for salmonella
Important nutrition crises
Bovine Spongiform Encephalopathy (BSE)
Dioxins in food chain
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Quality Control
FSMS
The Decisions …
The EU “White Paper” of year 2000The aim is to convert the European policy to an
preventive
dynamic
consistent
complete
tool for the consumer protection
Rule 178/2002 From the production to the consumers’ table
Integrated systems for tracking and tracing for the whole chain
Establishment of the European Food Authority and the National Authorities
Risk Analysis – Evaluation, Management, Information
European Union Guide 93/43/ΕΟΚ (HACCP) compulsory from 2003 and the total traceability from
2005
special guides per sector 91/497 &498, 92/46 & 47 etc.
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FSMS
The Rules …
From the “repressive” quality to the “preventive” quality
Creation of the Infrastructure
Staff training (ΚΥΑ 487/21-9-2000 ΦΕΚ Β’ 1219)
GMP (Good Manufacturing Practice)
GHP (Good Hygiene Practice)
SSOP (Sanitation Standard Operation Procedures)
Other special prerequisite infrastructures
Τhe H.A.C.C.P., (Prototype ELOT 1416, GuideEU 93/43)
A check tool that became pressing need
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Conclusions
Plant Vision
Quality Control
FSMS
The Need
Integration of distinct systems and technological support of their management
Specifications (formula, quality inspections, production, maintenance, cleaning, inspection and releasing, transportation and storage instructions)
Quality Inspection (inspection results)
Total traceability (lot’s labeling and recognition, quantity – time - component)
Asset management (machines, test instruments)
Certificates management
GMP (Good Manufacturing Practices)
GHP (Good Hygenic Practices)
H.A.C.C.P., decision tree and critical control points
Staff training
Customer’s complaints management
ISO, complete management
CARs Corrective and preventive actions
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FSMS
The Solution ”Food Safety Management System”
ISO – Document Management
Controlled document’s management, archives
Corrective actions (corrective / preventive / other)
SSM’s Supportive Safety Measures
Customers’ complains
Internal and external audits
Staff training
Other SSM’s (periodic actions such as maintenance etc)
HACCP functions
Hazards
HACCP Categories
Process Steps and Procedures
Food Safety Plans per item or HACCP category
Hazard evaluation (Decision tree)
HACCP Plans – critical control points
Quality Plans and quality inspections
HACCP system confirmation
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Εισαγωγή
Lot’s Tacking
Conclusions
Plant Vision
Quality Control
FSMS
Plant Vision FSMS
Conclusions
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Εισαγωγή
Lot’s Tacking
Conclusions
Plant Vision
Quality Control
FSMS
Conclusions
Why Mantis S.A. ?Because the accumulated experience on materials tracking and goods flow, ensures a successful implementation for “Plant Vision”
Why “Plant Vision” ?Because the value of the immediate information for the materials’ topology and the work flow in the production is important, provided that it can avoid bottlenecks, it can help to the normal operation of the factory and to the continuous work control
Why “Visualization” ?Because information needs to be displayed in a comprehensive and immediate way to facilitate immediate reactions
Why “Goods Flow Monitoring” ?Because the techniques and the technology of goods tracking within a warehouse, can be applied to the goods flow within the production process as well, resulting the complete and analytical lots traceability and the quantity supervision in the production process
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Conclusions
Plant Vision
Quality Control
FSMS
Summary
Why ”Plant Vision” ?Because is the only system that delivers what was always missing from any production management system!
Fast and immediate capturing of production data
Visual and graphical presentation of materials flow
Complete and analytical traceability of lots and S/N
Control of production efficiency
Integration with three data collection systems (PLC’s)
Integration with the ERP
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Conclusions
Plant Vision
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FSMS
and execution link with WMS …
Information flow in an integrated multi-system environment
Information support of the ERP
ERPFinancial Module
Commercial Module
MESInventory ManagementProduction Management
WMSWarehouse Management
Transportation Management
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Conclusions
Plant Vision
Quality Control
FSMS
When WMS and MES become one …
Our scope is the “intra” and “inter-plant” Supply Chain Management Solution!
MESInventory ManagementProduction Management
WMSWarehouse Management
Transportation Management
ERPFinancial Module
Commercial Module
…with the experience of a leader…
Thank you for your attention!