Industry 4.0 for the chemical and cosmetics sector

MES SYSTEM FOR THE CHEMICAL AND COSMETIC SECTOR

From MESbook we work with pioneering companies in the Chemical-Cosmetics sector in the application of our technology to solve their factory challenges and achieve good and lasting results. We achieve this by adapting our tool to manage their factories in real time and solve challenges such as maximizing the capacity of their production processes both in batch manufacturing of semi-finished products and in the serial packaging of their final products.

At the same time, ensuring that the recipes are executed accurately through automatic operator guidance and according to the quality standards required in each of the manufacturing and packaging stages and connecting the entire value chain for full control of traceability in the process. Our extensive experience in factories of the sector and methodology, ensures the successful digital transformation of their factories, enabling our customers to improve their bottom line.

Challenges in the sector

Eliminate paper: Manufacturing dossier with recipe, cycle time record, load verification, cleaning, packaging parts, Quality and Maintenance parts, traceability records, etc.
Connection of the entire value chain, from Reactors/Fusors to Packaging, for traceability control and monitoring.
Control of critical process variables in the manufacturing phase.
Digitalization of procedures and quality controls.

Maximize the capacity of your production processes: Minimize changeover and cleaning times.
Reduce manufacturing costs.
Energy transition and sustainability: Control of shrinkage, energy consumption, waste generation and water consumption.
Continuous improvement of its processes and products.

MES software solutions in chemical and cosmetic industries

Production system connected to machines and systems, processes, operators and raw materials.
Connection to machines and visualization of production progress and quality compliance by sections and machines.
Map of reactor states and control in the times of each phase.
Causes of productivity loss in real time: Automatic capture of stops and reasons for them: Product change, cleaning, breakdown, etc.
Connection to Scada systems for data capture and interpretation of productivity, consumption or process variable signals.
Sequencing of manufacturing and packaging, connected in real time with the factory reality.
Digitalization of recipes: Automatic guide for execution by the operator.
Digitization of the fundamental tools of LEAN Manufacturing

Digitalization of the Quality System and launching of control guidelines in the factory, according to the manufactured products and according to the lines where they are manufactured. Alert in case of any non-conformity.
Real-time monitoring of critical process variables (temperature, pressure, energy consumption, etc.), through which trends and deviations from the set nominal will be controlled, applying traditional SPC.
Real-time visualization of plant KPI's: Quality, Productivity and Costs, by section, line, family and product and their deviations with respect to the objectives set.
Calculation of cost variances by MOD and shrinkage, as well as the cause of variance in €.
Shrinkage control: Quantity per actual raw material Vs target quantity per raw material. Deviation and cause in €.
Paperless factory management.

Benefits of implementing MESbook in factories

REAL-TIME CONTROL

Real-time production control of the factory and the problems that occur, being able to act on them in real time.

Productivity Improvement

Greater control of the factory's production in real time and of the problems that occur, prioritizing those with the greatest impact and acting on them in real time.

Optimization of machinery

Machine availability by optimizing time spent on changeover times and cleaning through efficient planning.

RELIABILITY OF THE QUALITY SYSTEM

Reliability and robustness of the quality system, reducing time and costs associated with administrative tasks and audits.

COST CONTROL

Control and optimization of variable costs and visualization of deviations against the company target. Saving indirect costs related to data capture and management in the factory to convert it into information and knowledge.

TRACEABILITY CONTROL

100% traceability throughout the entire production process, from the manufacture of the semi-finished product to the packaging of the final product.

PERFECT RECIPE

Potential to link any variable that has been involved in the process and achieve what is defined as Golden Batch (Perfect Recipe, shrinkage optimization, direct labor costs or quality) through machine learning and advanced analytics.