Plant Monitoring & Performance Optimization

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Plant Monitoring & Performance Optimization …with the experience of a leader… The new software generation for the Industry

Transcript of Plant Monitoring & Performance Optimization

Page 1: Plant Monitoring & Performance Optimization

Plant Monitoring & Performance Optimization…with the experience of a leader…

The new software generation for the Industry

Page 2: Plant Monitoring & Performance Optimization

Home

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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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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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Conclusions

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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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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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.

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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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Plant Vision

Quality Control

FSMS

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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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

Quality Control

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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Quality Control

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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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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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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Quality Control

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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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

Quality Control

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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Plant Vision

Quality Control

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

Quality Control

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

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Conclusions

Plant Vision

Quality Control

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

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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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Plant Vision

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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Quality Control

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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Plant Vision

Quality Control

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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Conclusions

Plant Vision

Quality Control

FSMS

Plant Vision FSMS

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Conclusions

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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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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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Plant Vision

Quality Control

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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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

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…with the experience of a leader…

Thank you for your attention!