03.03.2017

Manufacturing Enterprises that are Made Visible through MES and ERP

With each passing day, we understand better the importance of keeping the structure that lives in every aspect of enterprises as data that can be transformed into information. Of course, it is essential that the collected data pass through necessary analysis processes and are transformed into information that can influence the processes and offer competitive advantage. We see and are happy that manufacturers who play a crucial role at this point also make changes in their strategies and move towards integrated systems, which will serve as the basis for digital enterprise.

Enterprise Resource Planning Software (ERP) and Manufacturing Execution Systems (MES) Software were conventionally two separate pillars of production technology puzzle. But in today's world, we see that they are beginning to emerge on joint projects to establish a basis for world-class quality and service. Many experts also share that ERP-MES integrations are invaluable technologies to perceive actual manufacturing needs and ensure the necessary synchronization.

At first glance, although these investments seem to be a long-term vision, especially since the concept of Industry 4.0 was introduced to our lives and it draws us to this point, it is evident from conversations that such investments will be realized by manufacturers in our country especially in 2017 and 2018, and this is a source of pride for all of us.

Thus, we will have created a fully visible enterprise where data will be kept in systems with such technologies, any error, bottleneck and delay will be easily found out and main business process will be analyzed.

If we are to go into further details, the most important parameters affecting productivity in our manufacturing enterprises are:

Downtime based on preparations,

Downtime based on failures,

Downtime based on errors,

Downtime based on lack of material etc. and

Downtime based on maintenance.

 

As examples of these causes:

Waiting for mold/pattern,

Electricity,

Mechanical problems,

Mold assembly,

Mold cylinder heating,

Inching,

Foil exchange,

Color change,

Mold failure,

Mechanical failure,

Robot breakdown,

Voltage drop,

Water cut / pollution,

Operator fault,

Raw material defect.

It is extremely important that all of these above-mentioned items are grouped into Machinery, Infrastructure, Materials and Production groups and they appear on the system in a single panel and Production and Downtimes are kept under strict control in the enterprise based on regular reports retrieved from the system.

It is clearly known that operations due to the dynamic structure-requirements of the process or the approach of "saving the day" during daily life result in serious  inefficiency and loss of money but it is seen that necessary technological investments are not made in order to reach  a solution in terms of taking action.

Without further ado and wasting your valuable time, I would like to share the following items/columns as examples that I suggest to be incorporated on the panel described above:

Machinery,

Tools (head / die)

Stock produced,

Production time,

Production rate,

Production quantity,

Unit weight,

Labor time,

The reason for preparation,

Preparation time,

Cause of failure,

Downtime,

Cause of error,

Error time,

Reason of lacking,

Duration of lacking,

Cause of downtime

Duration of downtime

 

Author: Ahmet Savaş Göktürk