Industry 4.0 for the metal sector

MES SYSTEM FOR THE METAL SECTOR

The metal transformation sector has some particularities that need to be treated with the industrial knowledge of having worked in it, such as how to measure the efficiency of a machining center when you are preparing the machine or how to manage the processes of automatic press brakes, among others.

This experience in the sector has allowed us to adapt our platform to the needs of the sector, providing a differentiating value for the client.

In this sector, the cost content of materials within the industrial cost structure is a significant value, so our cost control functionality on shrinkage is always a plus.

Not to mention the advantages of having a platform that covers the entire industrial life cycle of products, starting from the design part with the APQP 4.0 solution, through the entire manufacturing operational management platform to improvement management using LEANbook as a support for the LEAN methodological framework.

Challenges in the metal industry

Exploit to the maximum the investment in capacitive machines given their high CAPEX by finding the causes of wastage.
Robust machine set-up processes to identify the optimal solution for the highest and best product quality results.
Monitor and control through statistical models, those critical variables of the process.
Optimize and control energy consumption.

Measure the cost of product waste on each production order, each item or each machine to reduce the high cost of scrap that ends up in scrap or in the material recovery circuits with the consequent economic loss.
To be able to manage the sequencing and planning of machine loading for better machine utilization, taking into account resource constraints.
Paperless management.

Solutions with MESbook

Know at all times the status of production orders.
100% support to certification audits for IATF 16.949 and ISO 9100.
Automatic declaration of the main reasons for OEE loss.
Analysis of critical process variables (pressure, gas consumption, revolutions, temperature...).
Elimination of human errors in records through Hyper-connectivity of peripheral devices to avoid human intervention.
Continuous comparison of the cycle times defined for each part on each machine.
Alerts on errors in the definition of production cycle times.
Aggregate information that becomes knowledge for better decision making in the factory.

Productivity heat map identifying the bottleneck in continuous lines and detecting the process responsible for line stoppages and their impact on upstream and downstream processes.
Pareto of the main wastes and their costs in real time.
Real-time measurement of product change processes identifying each of its phases.
Digital management of control plans and traceability of self-monitoring.
AQPQ digital.
Flexibility in the creation of industry- and company-specific scorecards.
Digitalization of the fundamental tools of the LEAN Methodological Framework (LEAN Manufacturing, LEAN Design, LEAN Management and LEAN logistics).

Benefits of implementing MESbook in your plant

REAL-TIME CONTROL

The immediacy of the information facilitates the possibility of taking rapid action to prevent wasteful deviations from continuing to accumulate.

QUALITY MANAGEMENT

Keeping quality and non-quality costs under control is essential for the optimal design of control plans to ensure customer quality requirements at minimum cost.

RESULTS CONTROL

Data mining for the intelligent identification of results of productive operations to identify improvement plans.

SHRINKAGE CONTROL

Pareto display of raw material cost variances by different dimensions, by product family consumed, by product family manufactured, by line, by material consumed, by material manufactured, by production order, etc.

CONTROL OF PRODUCT CHANGES

It allows to take automatically and continuously the times of each operation of the product or format change processes.

MOD COST CONTROL

Identification of the Pareto of Direct Labor (MOD) cost variances for the main variances such as rework, rest overruns, non-allocation of work, labor cost delta, delta of people working or production speed variances.

PRODUCTION CONTROL

Guidance and direction to the operator for the correct and efficient execution of the production, where the operator can have all the necessary elements for his activity, such as planimetry, instructions, progress control, metrics and performance indicators, etc.

DATA HISTORY

To have all the data compiled as information to provide the necessary knowledge for correct decision making and development of improvement plans.

TRACEABILITY CONTROL

Traceability of quality assurance, manufacturing batches, people involved, review of self-checks not performed, performed late and their results throughout the production process.

OEE CONTROL

Control of machine utilization by automatically identifying, without human intervention, the main reasons for loss of performance such as breakdowns, changeover times, micro-stops, product shortages, personnel shortages, reprocessing, cleaning, production start-ups, etc.