FactoryIntegrate is an easy tool to use for planners, enabling the simple visualisation and sequence of the schedule laid out. Improving the communication of the planned schedule to production lines, users have the ability to create orders manually, download orders from the ERP system and schedule orders to lines, creating rules that ensure certain products are restricted to certain lines.
Viewing orders with common features and attributes is simplified, as well as viewing order lists and Gannt charts. With live scheduling, it’s easy to reschedule orders to run on different production lines – the effect on the schedule will instantly be re-calculated. Additionally, as the schedule is live, any changes will be immediately reported to the operator on the line – so they’ll always know what’s coming next.
Downtime is the single most contributing factor towards lost production, impacting profit – particularly for high volume, low margin manufacturers. The Downtime Module of FactoryIntegrate provides two levels of solution, and reports on a number of key elements related to downtime and the effects on production lines.
With the option to manually or automatically record downtime events, FactoryIntegrate allows operators to either record events directly in the system when they occur or before the end of the shift, or record automatically if connected directly to the machines.
Downtime events are easily classified into things such as breakdowns and equipment failures, technical reasons relating to equipment and process, quality-related, operational (when procedures are not followed), unplanned stops for material and resource shortages, and planned stops such as maintenance, change-overs and set-ups.
The reporting abilities of FactoryIntegrate are comprehensive, covering such reports as downtime Parento analysis by machine and reason, downtime trends (day, month, week, shift), Gannt charts, analysis of short and long stops, and related KPI’s.
Downtime
Benefits
Providing two levels of production counting, FactoryIntegrate allows users to manually or automatically record production quantities. Where manual recording is necessary, operators enter production quantities directly in the system as occurred or at the end of shifts, while automatic recording connects to equipment and provides real-time production counting.
With a powerful range of reports backing up the count, analyse the production reports by machine, line, department, shift, crew, reason and product. Review cycle time vs. target cycle time, production speeds, calculate KPI’s, and raise alarms via email/SMS.
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The spoilage module of FactoryIntegrate provides manual or automatic recording to allow operators to either manually enter spoilage information directly into the system when it occurs or at the shifts end, or automatically by connection to the equipment to collect reject counts at specific points.
Advanced reporting allows information to be captured on spoilage by machine, line, department, shift, crew, reason and product. Using this information, Spoilage Pareto analysis by machine and reason can be analysed, as well as spoilage trends, calculating KPIs and raising alarms by email/SMS when required.
When used with other modules the Spoilage module of FactoryIntegrate, such as Downtime, Production Counting, and OEE modules, the Spoilage module can deliver real-time OEE reports giving you the power to prompt action on undesirable events.
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FactoryIntegrate provides a Line Log Book module solution that defines a number of different types of events to record – shift handover comments, tool changes, intervention and cleaning. It allows events and comments to be recorded at any time, and all of them are recorded with personnel, time –stamped, recorded in the context of machine and line.
Develop a comprehensive event history against the line for all to see, as well as configure the system to take automatic signals to record events, and all reports can be pulled together and reported on as one.
Benefits
FactoryIntegrate provides a Line Log Book module solution that defines a number of different types of events to record – shift handover comments, tool changes, intervention and cleaning. It allows events and comments to be recorded at any time, and all of them are recorded with personnel, time –stamped, recorded in the context of machine and line.
Develop a comprehensive event history against the line for all to see, as well as configure the system to take automatic signals to record events, and all reports can be pulled together and reported on as one.
Benefits
This solution from FactoryIntegrate allows users to define target manpower requirements on the product routing, allowing reports to compare planned manpower with actual manpower. Easily record operators’ actions such as logging on or off a production line, cell or work centre, capturing the duration. Operators can even move between lines, managing several lines at once or be wholly reassigned to a line.
Benefits
Easily create and record inventory with FactoryIntegrates Inventory Module. Creating records for each pack of inventory created (including semi-finished goods and finished goods) and automatically attach traceability details.
Create inventory records when goods are received, and attach details for optimum traceability such as supplier, supplier lot number and supplier traceability information. Inventory is flexible and able to be changed using a set of user defined states, where a complete history of the state of the inventory is recorded – who made the decision, when and where.
The software also assists keep track of locations and bins, best-before and use-after dates and creates a seamless link to other warehousing systems or ERPs.
Benefits
Inventory Visibility: From received goods to finished goods, inventory is able to be located
Traceability: Know which inventory was created when and where
Production Reporting: Track inventory created as the primary record of production, and generate production records
Isolations (Quarantines): Ability to isolate goods quickly and ensure they do not escape into the logistics cycle
History: Creates history of data – how often has something been quarantined, where does it occur and for what reason
Continuity: Managing inventory in the MES layer means that the factory can still produce even if there is an ERP system outage
The Warehouse module of FactoryIntegrate is an extension of the Inventory module, and builds upon the inventory management to provide information about in-bound deliveries, out-bound deliveries, warehouse and local stores management, movement orders and packaging and hierarchical handling units.
Integrating with existing ERP systems, in-bound deliveries can be downloaded right down to the level of individual handling units (boxes, pallets etc.) and when deliveries arrive, unloaded goods can be scanned and goods can be validated against planned deliveries.
Fork lift drivers can select from prioritised shipping lists and work through picking lists, scanning the units as the goods are loaded onto transport. Messages can be sent to the ERP system to confirm and out-bound delivery.
Materials are tracked in warehouses and local stores, showing summaries of stock levels, and expected in-bound and out-bound deliveries.
Movement orders can be generated and sent to raw material stores in order for consumption and replenishment internally. These can be manual or automatic material orders. Workers work from prioritised lists to select a movement order and work through pick lists to load materials onto internal transport. Master data also decides how the order needs to be filled – minimum quantities, packaging and ship to locations, timescales.
It is also possible to have a hierarchy of inventory, for example serialised items in a box, or boxes on a pallet.
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The label printing module of FactoryIntegrate has the ability to print labels automatically at the point of production, on demand. Shopfloor-Online knows the production order being executed, the specific label design, traceability information, the shift, production line, and it can also generate the unique serial number for the goods.
It automatically selects the correct design, generates serial numbers, prints multiple labels, sends labels to the correct printer, reprints damaged labels, product information or safety notices and integrates with ERP systems to upload WIP and finished goods.
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One of the most important and least used tools of LEAN manufacturing is Standardised Work. Put simply, standardised work embraces the principles of lean and flow production in standardising the method or sequence in which the job is done.
The FactoryIntegrate Standardised Work module allows users to document and guide workers through a series of predefined steps, and establish precise procedures for operators work in the production process.
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Vision systems are now considered to be an essential part of many industrial processes, and ofer faster, improved and reproducible inspection capabilities at a competitive cost. The FactoryIntegrate Smart Vision module provides an integrated hardware and software platform to ensure Quality control.
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