Comarch IoT MES

• Production and planning

  • Missing up-to-date information on production downtime (effect: production delays)
  • Missing information on the actual working cycles of machines/production lines
  • No ability to react quickly to production problems and prevent them proactively
  • High costs of manufacturing
  • Lack of knowledge about the current progress and efficiency of production
  • Production waste
  • Incorrect performance data
  • No awareness of real production costs
  • Low OEE
  • Data inaccuracy, errors, and delays resulting from manual planning and data entry
  • No control over the actual levels of resources needed for production that are located in the plant

• Management

  • No real-time control over production
  • Insufficient amount of management data (to make business decisions)
  • Need for additional hourly shifts due to production delays

• IT

  • Implementation of multiple, diverse production systems
  • No possibility to integrate data between multiple systems
  • Unintuitive interfaces of different systems
  • No flexibility and customized system modifications

• Quality

  • No control over emerging manufacturing defects and downtime
  • Production waste
  • Manual reporting affecting process efficiency and quality
  • Customer complaints and returns

Implementation benefits

• Integration with an ERP system

  Connecting ERP and MES systems has never been so easy. As the producer of Comarch ERP systems, we allow them to be quickly integrated with the MES software. Comarch MES also cooperates with other popular ERP systems. As a result of system integration, production orders are sent directly to machines, allowing you to get rid of paper documentation. 

  What are the benefits of integrating MES and ERP systems?

  • Real-time access to the status of production orders
  • Production reports sent to the ERP system straight from machines
  • Elimination of paper documentation
  • Up-to-date information on periods of downtime, their reasons, and real costs
  • Insight into information on shortages emerging in the course of the production process
  • Saving of time spent on reporting
  • Access to accurate, up-to-date, and consistent data 

• Integration with production lines

  Thanks to various methods of connecting with machines, we obtain real-time production data such as the status and time of work, alerts, and information on the number of pieces produced. It is possible to install additional sensors on production lines or use existing interfaces such as OPC UA, Siemens S7, TCP, Modbus, etc. The method of integration is selected together with the client, depending on the process and type of machine.

• Reduction of paper documentation

  Many stages of the production process involve the creation of extensive paper documentation, including production plans, orders, or operations, the excessive amount of which contributes to human error, thus extending the paper data circulation. Therefore, the digitization of the document workflow is one of the ways to increase control over access to data/documents, improve information security, and eliminate the risk of destruction or loss of documentation, simplifying and accelerating the entire data workflow, while eliminating the existing costs of handling paper documentation.

• OEE measurement

  The OEE indicator is one of the most important coefficients for measuring production efficiency. OEE is calculated as the product of three manufacturing components: availability, quality, and performance. Analysis of the OEE indicator allows the detection of bottlenecks, which limit the overall efficiency of production lines. Also, it shows where losses occur in the production process. Calculate OEE, define other indicators, and track them all using Comarch IoT MES.

• Production data available in real time

  Data about the production in progress and the status of a production order are collected and provided to the user in real time. Information is retrieved directly from machines, so it is possible to react immediately to any undesirable phenomena occurring in the production process, such as unplanned downtime, failure, or decrease in productivity.

• Improvement of production quality

  The production of good quality products depends on a number of factors. The quality control module allows you to digitize and control selected stages of production orders, contributing to the maximum automation of information flow and final identification of the production process (product traceability).

• Enhanced performance

  Process performance depends on many factors, so real-time reports are particularly important. Gathering production data and monitoring machine operation helps to make more accurate decisions and respond in real time to problems that arise on the production floor. The desired end result of such activities is the ability to fully utilize the plant’s production potential.

• Tracking downtime

  Very often, downtime results in delays in production and a decrease in performance. MES automatically records all downtime based on signals sent by machines, having real data about the reasons for the downtime; therefore, it is possible to eliminate production interruptions immediately and optimize the time required for an operator to manually report the status of a machine.

• Reports of actual production data

  A production report provides complete information, presented in graphic form, which allows you to look at the factory from different perspectives. Check OEE, availability and quality in reference to specific production orders, machines, departments, or the entire factory. The system allows you to create a report for the most important indicators in any period, such as the last shift, the entire week, or month.

• Andon boards

  Andon boards are used to display production processes and monitor the performance of the operators of individual production lines and those responsible for resolving discrepancies throughout the production process.

  The screen displays not only colors (green, yellow, red) indicating the status of individual cells/workstations, but also key indicators regarding: 

  • Production efficiency, level, and quality
  • Status of production machines
  • Planned and actually produced quantities of manufactured items
  • Time since the last warning, downtime, failure (including their causes)