Takes a production order from release to completion.
What to run, on which line, in what order. Operators book progress on shop-floor screens that update live, and supervisors see the plan against reality. Every unit keeps a record of where it ran and what happened to it, and finished quantities flow back to your ERP without anybody re-keying them.
In daily production across multi-site manufacturing groupsThe problem it removes
The plan is in one system. What actually happened is in a folder.
The order comes out of the ERP, the line does what it can, somebody writes the result on a sheet, and a day later a person types it back in. Between those two points nobody can say what is running, what it is waiting on, or why the line stopped for forty minutes on Tuesday.
An order has a state, and everyone sees the same one
Not started, running, stopped, finished. The state is a fact about the order, not something inferred differently by each screen looking at it, so the office and the line are never describing two different realities.
Screens that update themselves
Line displays and operator terminals change as the line changes. Nobody refreshes anything and nobody works from a picture that went stale twenty minutes ago.
The plan against reality, side by side
The planner sees the sequence that was intended and the sequence that is actually happening on one screen, which is what makes a reordering decision possible before the shift is lost rather than after.
Every stop gets a reason, and the reasons compare
Stops are classified into a category, a type and a reason, with room for the codes a particular plant needs. The operator classifies once, and the analysis still adds up across plants that do not run identical lines.
Traceability per unit, not per shift
Every unit carries the record of where it ran, when, how long it took and what interrupted it. A complaint six months later is answered from the record instead of from memory.
Finished quantities go back without re-keying
Completions and revised speeds are written back to the ERP automatically, which removes both the typing and the transcription errors that come with it.
What it does
Every corner of running the orders.
Orders
Release, run, stop, finish
The lifecycle is enforced in one place, so the shop-floor screen, the planner and an imported plan all move an order the same way and cannot leave it in a state that makes no sense.
- One lifecycle for every route in
- Stops and restarts recorded, not overwritten
- Reason required where you require it
Traceability
A record per unit and per interval
Every interval of production writes a row, every change of state writes a marker, and every process keeps its start, its end and its reason. Auditable from end to end without a reconstruction exercise.
- Who, when, how long, why stopped
- Survives shift and day boundaries cleanly
- Answers a complaint months later
Planning
The sequence, and the reality next to it
The plan arrives from the ERP or is built here, and the planner works it against what the lines are actually doing rather than against yesterday’s assumption.
- Plan imported without re-keying
- Resequencing while the shift is live
- Per-line and per-plant views
Shop floor
Screens built to be read from a distance
Large line displays for the floor and detailed terminals for the operator, both updating on their own as the state changes.
- Line displays and operator terminals
- Live, without refreshing
- Readable across the hall
Downtime
Category, type and reason, with local codes
A structured tree that a plant can extend where it genuinely differs, so local accuracy does not cost group comparability.
- Three levels, consistently applied
- Per-plant additions where needed
- Still comparable across sites
Reporting
Last year answers as fast as last shift
Historic figures are prepared in the background on a regular cadence, so a question about the last twelve months does not take longer than a question about this morning.
- Prepared on a schedule, in the background
- Recent data available as it lands
- Fast even at group volume
How it runs
It installs on the same plant appliance as the machine data collection, in one pass, and needs nothing from outside the site to keep the shift going. Sites with their own cluster can run it there. Each plant holds its own data, and the group view is assembled from the plants rather than depending on them staying connected.
Works with the rest of the range
It reads the state the machine control publishes and the values the plant-floor collection records, drives the screens on the floor, and hands finished quantities back to the ERP. The same figures roll up into a group reporting cockpit, and an automation can raise the right person when a job drifts off plan.
How to start
One line, one order type.
Run a single order type on a single line end to end, from release to completion booked back into the ERP. That is normally enough to size the rest of the plant.