In today's demand-driven industrial business environment, companies are seeking to introduce advanced systems to achieve excellence in production organisation and quality. The most widely used tool is a MES (Manufacturing Execution System), a software that interposes itself between the management system (ERP) and the factory, collecting and managing large amounts of data related to the entire production process.
Our client, a leading family-owned company producing agricultural machinery, was seeking to improve production efficiency by saturating production capacity and reducing production batches, with the ultimate goal of offering better service to customers with the full involvement of key users.
To ensure an effective introduction of the new software, the preparation phase consisted of:
Software selection was followed by installation and a period of testing, during which two "pilot" workstations were used to put the system to the test: one for the "Machine Tools" department and one for the "Assembly" department. This intermediate step made it possible for key users to test all of the software’s features in a working environment and to make the last necessary customizations.
This "trial" period was indispensable and of great value. It allowed operators to learn in detail how the MES works and to evaluate all of its aspects, both positive and negative. Thereafter, the focus was on making activity records more fluent and intuitive, thus maximising the chances of user acceptance. The opinion and cooperation of the operators were key to building a system that was simple, effective, and within their expectations.
Once the final structure was determined, it was possible to complete the installation in all production areas and to train all users, thus bringing the system up to full capacity.
With the introduction of the MES software, accurate information on production progress has been obtained in a paperless way, allowing for complete tracking of downtime in "real-time."
The data generated daily by the 15 computers installed in the different departments allows for in-depth analysis aimed at reducing major downtime (such as set-ups or breakdowns), in particular in the 2 departments:
Here are some of the benefits that have resulted from the application of MES in the Company:
For the company, the adoption of an advanced system such as a MES has allowed for important progress to be made in terms of computerization and process efficiency improvement. Given these benefits, the implementation of a scheduler is already being studied with the same software house to improve the management and organization of production for a further increase in the quality of the product and service provided to customers.