Factory Integrate

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

• React faster: Because information is made available to you in reporting functions, even in manual recording environments
• Improved accuracy: Downtime event occurrences, durations, reasons – all reported on to improve decision making in an event
• Short Stops: More visibility of the impact of hidden losses of short stops and how that impacts the business
• History: Develop a detailed events history for continuous improvement teams to analyse
• Visibility: Dashboards ensure that everyone sees the same information at the same time
• Saves time: Automatic data collection removes the need for timely manual reporting processes
• Dual-mode: FactoryIntegrate allows some lines to have data collected automatically while others are collected manually, meaning where the pay-off is likely to be higher automatic methods can be used, and where not so high manual mode is more appropriate.
• Reduce conflict: One document, one truth, no personal perceptions and shared by all.

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.

Benefits

• Faster reaction times: Improve the immediacy of production information such as speeds and cycle times
• Avoid over-production: Because you’ll know what is made with real time production counting
• History: Production performance in line with powerful reports allow Continuous Improvement teams to identify action areas
• Save time: With automatic data collection
• Dual-mode: FactoryIntegrate allows some lines to have data collected automatically while others are collected manually, meaning where the pay-off is likely to be higher automatic methods can be used, and where not so high manual mode is more appropriate creating a plant-wide unified spoilage recording system .

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.

Benefits

• Act: Know when and where losses are occurring so that action can be taken
• Faster reaction times: The immediacy of spoilage information allows for faster reaction times, even in manual recording modes
• Visibility: Dashboards display email alerts and ensure that high levels of loss don’t go unnoticed
• History: Provides a detailed history of Spoilage for Continuous Improvement teams to action
• Save time: Automatic data collection allows you to save time and focus on more important issues
• Dual mode: Dual-mode: FactoryIntegrate allows some lines to have data collected automatically while others are collected manually, meaning where the pay-off is likely to be higher automatic methods can be used, and where not so high manual mode is more appropriate creating a plant-wide unified spoilage recording system .

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

• Communication: Improves communication between shifts and between management and operators – where the event histories are accessible and legible
• Visibility: Hand-over logs and any issues accompanying it can be seen by all and accessed from anywhere
• Traceability: Record important events that happen in the production process
• Go paperless: Record issues and logs by system rather than on paper, with a more accurate and professional system

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

• Business gains: Small gains can have a dramatic effect on capacity and performance improving on such things as on-time deliveries, reduction in shifts and overtime, and avoiding or deferring asset purchases
• Identify problems: OEE is calculated and reported, broken down by availability, production and quality rations so losses can easily be seen
• Faster reaction times: With real-time data collection it’s easy to calculate OEE and major losses show up instantly
• Visibility: High levels of losses don’t go unnoticed with dashboard displays and email/SMS alerts
• Save time: Automatic data collection means no more timely manual collection and calculations
• History: A detailed history of losses and reporting allows Continuous Improvement teams to identify areas that need working on.
• KPIs: Make OEE visible in real-time so everyone knows how the plant is performing

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

• Labour Costs: Track labour hours and calculate manpower costs per job
• Exception Management: Is reports to see where labour costs deviate from planned costs
• Traceability: Operators record the lines they are working on and automatically the Line Labour Tracker captures people related traceability data

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.

Benefits

• Business Continuity: provide that connection between the ERP system and the manufacturing process
• End-to-end Traceability: Tracking units all the way through the logistics and manufacturing cycle, including knowing what is being consumed, how and when
• Stock Control: Greater control of inventory right down to a handling unit level
• Facilitate LEAN Logistics: Movement orders pulling materials from warehousing and stores

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.

Benefits

• Improved Traceability: The system knows all of the traceability information at the time of printing and accurately prints it onto the label.
• Reduced Effort: Eliminates the pre-work of label printing
• Fewer Mistakes: Always prints the correct label, with the right information, every time
• Less Waste: Because printing is on-demand, every label printed is used
• Real-time Visibility: As each label is printed on demand, you have a real-time picture of production, making it possible to track production rates and from there OEE reports

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.

Benefits

• Capture employee knowledge so it becomes a corporate asset
• Enhance productivity
• Maintenance and improvement of quality
• Reduce waste, cost, injuries, strain and variability
• Easy to train newer operators
• Provides a baseline for continuous improvement activities
• Comprehensive activity process variability reporting