Production monitoring
Overview with insight: Production monitoring as the key to a transparent factory
Production monitoring is the key to efficient, transparent and flexible production. It enables companies to increase their competitiveness and successfully meet the challenges of the modern production world.
With the help of modern MES solutions, production monitoring provides deep insights into the manufacturing processes – from planning the optimal utilization of machines to the real-time recording of relevant production data and the visualization and analysis of the results. This enables bottlenecks to be identified at an early stage, resources to be used more efficiently and quality standards to be increased. Factory teams can adjust production parameters in real time and thus actively respond to changes.
How does production monitoring work?
Production monitoring is like conducting an orchestra: just as a conductor directs the interaction of many musicians and their instruments, production monitoring ensures transparent and efficient control of all processes in production.
The task of production monitoring is complex. Many factors play a role – the product itself, market requirements, legal regulations. Various components such as detailed planning, visualization, data collection, energy monitoring and production control are therefore crucial.
Planning: Laying the foundations for efficient production
Detailed planning is essential before production starts. It defines production targets, plans resources and processes and draws up production schedules.
Precise planning forms the basis for all further steps in production monitoring and is crucial for
- Efficient use of resources: forward planning avoids material bottlenecks, idle machine times and unnecessary storage costs.
- Optimized production times: Clear time specifications and coordinated process planning enable faster and more efficient production.
- Transparency and traceability: A detailed production plan provides everyone involved with a clear overview of the planned production process.
Visualization: Making the production process tangible
Visualization makes the production process transparent and easy to understand. Graphical representations, diagrams and key figures are used to prepare complex data and present it clearly. This enables
- Rapid problem detection: deviations from the target status become immediately visible through visualization and allow timely intervention.
- Improved communication: The visual representation of production data facilitates communication between the various departments and lays the foundation for well-founded decisions.
- Greater employee motivation: A transparent presentation of production progress and target achievement has a motivating effect on employees.
Recording: Digital real-time data as the foundation for optimization
The basis for effective production monitoring is the continuous collection of relevant data. This includes machine-related data such as production figures, machine utilization and downtimes, as well as process data such as throughput times, error rates and material consumption. Data is recorded by
- Sensors: these record data directly at the machines and enable real-time monitoring of the production process.
- Manual input: In some cases, data is also recorded manually by employees, e.g. during quality checks.
- Integration of ERP systems: The connection of ERP systems enables access to other relevant data such as order data and stock levels.
Monitoring: Directly on the pulse of production
Monitoring is a core element of production monitoring. Here, the recorded data is evaluated and analyzed in real time and compared with the planning specifications. Monitoring tasks:
- Detect deviations and faults at an early stage: Continuous monitoring quickly identifies problems such as machine breakdowns, material bottlenecks or quality defects.
- Create root cause analyses: Using the recorded data, the causes of deviations and faults can be analyzed and rectified.
- Identify optimization potential: Analyzing production data enables weak points to be identified and measures to improve process efficiency to be derived.
Control: effective countermeasures in the event of deviations
Based on the findings from monitoring, measures are then introduced to control and optimize production. These include
- Real-time interventions: in the event of acute problems, monitoring can be used to send control commands directly to the machines, e.g. to stop production lines or adjust parameters.
- Manual adjustments: In some cases, manual adjustments by employees are necessary, e.g. rectifying minor faults or readjusting machines.
- Process optimizations: The analysis of production data makes it possible to identify optimization potential and initiate measures to increase efficiency, quality and flexibility in production operations.
MES from FORCAM ENISCO: A holistic approach to production monitoring
FORCAM ENISCO’s MES solutions offer companies in the manufacturing industry a comprehensive solution for planning, visualizing, recording, monitoring and controlling all relevant production processes. Seamless integration into existing ERP and shop floor systems enables companies to significantly increase transparency and efficiency in their production.
- Detailed production planning: MES solutions enable the creation of detailed production plans, taking into account resource availability and production orders.
- Digital planning board: The clear planning board visualizes all planned, current and completed orders and enables intuitive planning and adjustment in real time.
- What-if simulations: Simulations can be used to run through various scenarios and analyze the impact on production planning.
- Real-time dashboard: The dashboard provides a central overview of all key production figures, such as OEE, scrap rate and throughput times.
- Interactive charts and diagrams: With the help of interactive visualizations, complex production data can be presented in a simple and understandable way.
- Mobile views: Important information and key figures can be accessed anytime, anywhere on mobile devices.
- Automated data acquisition: Our MES solutions and AC4DC enable the automated acquisition of machine data, operating data and process parameters via interfaces to machines and systems.
- Manual data acquisition: In addition, employees can make manual entries via user-friendly interfaces, e.g. for downtimes or material consumption.
- Barcode and RFID integration: The integration of barcode and RFID systems enables efficient and error-free identification of materials and products.
- Real-time monitoring of production: MES solutions enable all production processes to be monitored in real time so that deviations and problems can be detected at an early stage.
- Automatic notifications: In the event of critical events such as machine breakdowns or material bottlenecks, those responsible are automatically informed by SMS, email or push message.
- Performance analysis: With the help of detailed evaluations and reports, the efficiency of the systems and production output can be continuously analyzed and optimized.
- Manage production orders: MES solutions enable the management of production orders – from order release to delivery.
- Control material flow: The material flow can be tracked and controlled in real time to avoid material bottlenecks.
- Quality assurance: MES solutions support the implementation of quality checks and documentation along the entire production process.
The advantages of MES at a glance
- Greater transparency and better traceability in production
- Improved production planning and control
- Reduced downtimes and fewer production losses
- Optimized resource utilization and materials management
- Increased product quality and customer satisfaction
- Solid data foundation for continuous improvement processes
- Plus: Sustainable management can be documented in a traceable manner
By using MES (SAP Digital Manufacturing, MES FLEX, MES LITE and E-MES) from FORCAM ENISCO, companies can optimize their production processes, increase their competitiveness and position themselves for the future.