Dedicated production management

The project encompasses various functionalities, including the ability to queue production orders, display information about the current production order for each production nest, and monitor the status of materials, raw materials, prefabricated products, and finished goods. The MES system also facilitates managing the production supply process by foremen to individual production nests and enables quality control during production. Additionally, the software provides operators with workstation instructions specific to the current production order.

Client:

Industry:

Manufacturing

Technologies:

.NET, ASP.NET MVC 5, C#, Entity Framework 6+, Semantic UI, SignalR, SQL Server, Vue.js, Windows service host, WPF

Poland

Georg Utz Sp. Z o.o. is a renowned company specializing in the manufacturing and distributing transport containers, pallets, and plastic parts. They are dedicated to creating robust and practical storage and transportation solutions. Their wide range of products has applications in various industries including automotive, electronics, food, pharmaceutical, agriculture, distribution, and trade. Georg Utz is committed to delivering high-quality and customized solutions to meet the unique needs of their customers.

What was the business need?

Activities in Georg Utz Sp.z o.o. ‘s technology area aimed at creating a new production management system. The new platform was to be fully integrated with the current ERP system database and the future WMS system.

What was the challenge?

Communication between the Production Planning Department, the Warehouse, and the shop floor was carried out through several channels: telephone, paperwork, personal visits, and email. As a result, there were often misunderstandings, delays, and a lack of activity synchronization.

Previously, feedback on production status, such as completed orders, production waste, and consumed materials was collected in a declarative manner by operators and foremen, and then transferred manually on paper to the Production Planning and Control Department.

In the Planning Department, this information was manually entered into the ERP system to calculate Key Performance Indicators (KPIs) and Overall Equipment Effectiveness (OEE). However, due to the manual process of data collection and processing, the quality of this information was often poor, preventing long-term analysis and optimization of the process.

The lack of reliable production data created a whole series of further problems such as:

dispersion of knowledge regarding the current production process – often the continuity of production is based on one key person on the shift. Without them, the production process is halted or delayed,
lack of standardization of information flow between different work centers,
problems with optimization of the production process and waste due to lack of reliable data,
impossible for the management team to work remotely, as all production data is only available offline at the plant.

What was the solution?

The solution implemented in three areas proved to be effective:

Core System – a dedicated application that integrates data with Microsoft AX ERP and the WMS system (WMS feed in PW and RW).
Web Application – an administrative panel accessible through a web browser. Key functionalities include:
• Managing production orders, including assignment to individual slots and real-time status display.

• The Gantt chart panel on the production floor provides information on production orders executed on individual nests.

• OEE and KPI reports and their configuration.

• Quality control management.
WPF application

designed for Windows tablets

• the tablets serve as an interface for data entry by machine operators and foremen. Key functionalities include:

– Displaying assigned production orders, packing methods, progress status, production standards, and station instructions.

– Ordering materials for production slots.

– Entering predefined downtime causes for subsequent OEE reporting.

– Displaying notes with additional information on specific production orders from the Procurement/Production Planning Department.

– Logging in using a PIN, barcode card, or NFC card with local or Active Directory domain accounts.

What did the client get?

The implementation of the MES system has brought significant improvements and positive impacts across various areas of production:

Waste Reduction and Downtime Reduction: There has been a decrease in waste and a reduced downtime associated with ordering materials. The system helps streamline material ordering processes, ensuring timely availability and minimizing production disruptions.
Remote Work Capability: The MES system enables the management team and office staff to work remotely. They can access the system’s functionalities and monitor production processes from any location, enhancing flexibility and productivity.
Integration with Dynamics AX Database: Integration with the customer’s Dynamics AX database allows for automatic retrieval of production orders and Bill of Materials (BOM) data from machines. This improves machine management and ensures accurate transmission of production order instructions.
Improved Reporting and Quality Control: The MES system enhances reporting capabilities, enabling more efficient scheduling of quality control tasks and providing accurate reports on material consumption. This improves data visibility and facilitates informed decision- making.
Industrial Tablets and Administration Panel:
The implementation of industrial tablets and the creation of an
administration panel has streamlined reporting processes. Operators
can submit accurate reports and obtain specific machine
information conveniently, improving data accuracy and accessibility.
Overall, the MES system has positively impacted information
flow, work efficiency, waste reduction, remote work
capabilities, integration with other systems, reporting
accuracy, and quality control processes.

Are you interested in our services?

If you are interested in custom software design and development services, please contact our experts.

Together we will assess which of the SOFTIQ team’s competencies will support your project.

Dedicated production management

What was the business need?

What was the challenge?

What was the solution?

What did the client get?

Are you interested in our services?

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