What does planning module do?

ProManage planning module is supported by production plan and production plan (vertical) screens. The purpose of the planning module is to prevent delays in orders via ensuring the distribution of work orders based on available machines in accordance with the priority of customer orders and the availability of resources, such as operators and machines and etc.

Why planning module should be used?

Inability to catch up with orders is the main problem that emerges during manufacturing. Ignoring the insufficiency of resources, giving a task to a resource in more than its capacity or being uncertain of when a resource will finish a task prevent orders from being on-time. This, in return, leads the company to lose time and money constantly.

Executing the manufacturing plan on a live system, tracking it moment by moment and making a schedule in line with the production capacity will prevent the occurrence of losses. In addition, knowing when the next order will start in accordance with the information on when the current task will be over and organizing resources accordingly would also increase manufacturing effectiveness.

Impact of planning module on production

With the ProManage planning module, production plans can be tracked via managing them in line with a certain organization on daily or hourly basis. Through tracking factors, such as machine, operator, mold suitability and etc., that form production capacity, assignment of work orders is carried out appropriately. Hence, accumulation and delay in production and losses that stem from these will be prevented. Instant information on the process can be obtained through tracking the status of the process via taking the effect of performed production on time and the remaining production into account. The problems that will emerge will be determined beforehand and the necessary interventions are made in advance.

What does business monitoring module do?

ProManage’s online features allow users to determine a machine’s current status and speed from the production signal. Thanks to this module, simultaneous monitoring of the instant statuses of all the machines is ensured. With its various features, users could be able to personalize the numbers of screens and organize their requirements in a more specific manner.

The module provides information on the machines’ current production to the operators and technicians at a factory. Also the notification system kicks in using the online data.

Why business monitoring module should be used?

In order to manage the current statuses of the machines at a factory, the production responsible at the manufacturing area must have information regarding all the machines. Production teams are responsible for the interim machining when there is an unexpected disruption. By means of online tools, users can define problems and decrease their response durations.

With its customizable features, users can see the online indicators to track the machines’ KPIs. Through these KPIs, necessary specific interventions can be performed via viewing the machine’s energy, production, work orders and product information. In addition to demonstrating the TEEP and OEE values with indicators, users are able to see the machines’ TEEP and OEEs from online reports.

Impact of business monitoring module on production

Since the aim of MES is to increase the machine efficiency, the online monitoring tool of ProManage provides a cockpit screen to users where the machine status can be seen and fixed as soon as possible. From ProManages online tools, users will be able to determine the problems and fix them as soon as possible, hence achieving the main objective of manufacturing, that is the machinery running constantly.

They can ensure the correct management of data that allows them to go deeper into the root cause analysis to find the main reason behind the emergence of the problems. Meanwhile, monitoring the unplanned acts carried out in manufacturing and preventing them from the automatic warnings system. It ensures that the production team is notified when a wrong operation takes place, thus making sure that it gets fixed in the shortest time. In the long run, this will ensure that losses are decreased and manufacturing productivity and profits are increased.

What does machine stoppage history do?

Machine stoppage history ensures visualization of machines’ stoppages on the timescale axis. It makes sure that the stoppages of all the machines or those in formed machine groups are examined and that they are compared with each other. The following information on stoppages can be viewed on the machine history screen after the cause of a stoppage that is desired to be examined is filtered:

• Stoppage frequency
• The machines that stop most often
• The shift that stoppages take place most often
• The time period of the shift that stoppages become more frequent
• Stoppage start and end time, its duration and operator information

Why machine stoppage history should be used?

The duration, frequency and times of machine stoppages provide clues on their root causes. Analyzing the root causes of stoppages is the only way to eliminate them completely.

Moreover, it’s necessary for the predetermined stoppages (meal breaks, breaks, setup, shift ends and etc.) to be reported on machine-shift basis and sharing of the visual results with the operators

Impact of machine stoppage history on production

The sharing of stoppage histories with the operators lead an increase in the employees’ sense of awareness and responsibility and contributes to the formation of a beneficial competition environment.

Laying emphasis on machine stoppages and their causes during the Asekai and Gemba meetings supports making root cause analysis and increasing awareness.

As the awareness and sensitivity towards machine stoppages increase, machine, labor and production losses decrease, while productivity increases.

What does machine history do?

Machine History ensures machine and time based tracking of the stoppage, scrap, operator input, cycle and performed product/operation information of the time period that is desired to be analyzed. It reports a machine’s history through displaying its functioning in the related time interval.

It ensures that the following questions are visualized on the time axis and all situations are associated with each other within the visualized time interval:

• Which product/operation was worked on?
• When was the work on product/operation launched and terminated?
• Which stoppages took place, when did they start, when did they end and how long they lasted?
• Which operator/operators worked in which time interval?
• What’s the amount of faulty production and their reasons for occurrence?

In addition, it ensures examination of all performed cycles’ cycle durations in the cycle unit used specifically in the factory (second/cycle, cycle/second, minute/cycle, cycle/hour and etc.). It enables the examination of the performed cycles’ distribution and cluster graphics on histogram via matching them with the operator and product.

Why machine history should be used?

Online tracking of machine statuses carries significance in terms of preventing production losses and taking rapid actions if losses occur. In the cases that online tracking is not possible, shaping the recent past and displaying the current situation bear importance. The operator responsible of the machines, shift supervisor, department responsible, production responsible and factory responsible’s tracking a machine’s status and adopting necessary actions must be parts of the factory culture. For instance, the factory’s status during the night shift, machine stoppages and performed production information must be tracked without delay and necessary feedbacks must be realized.

Impact of machine history on production

The tracking of machines, manufacturing operations, stoppages and scraps lead to the formation of awareness and intuitively to improvement. Raising awareness as a culture and tracking the unfolding situations are the first steps towards increasing productivity. Tracking machines via Machine History, giving feedback to the operators and releasing of outputs play a crucial role in the formation of a culture in a factory through increasing awareness. Taking rapid actions in line with these pave the way for the prevention of losses intuitively and manufacturing operation in high quality and low cost.

What does reporting tools do?

With ProManage reporting tools, the following functions can be carried out:

• Tracking and analysis of machine productivity values
• Analysis of stoppages’ durations, amounts, MTBF, MTTR, FR, FFR and causes
• Reporting of faulty production in units of amount, time and kilograms and analysis of causes, PPM ratios and FTT values
• Root cause analysis
• Distribution of each cycle time that is realized based on machine/product/operator and SPC analysis
• In addition to basic functions, such as making the analysis of production amounts, speed and achievable amount in changing durations and performances, plenty of reportings can be carried out in order to increase manufacturing effectiveness.

ProManage Manufacturing Operations Management System’s reporting tools are flexible in terms of the users being able to realize their desired choices and combinations and this way, generating private reports that they can compare all values with each other through going out of the standard molds.

The user being able to generate reports based on products and work order information play a significant role in low-cost manufacturing via removal of the root cause and the in the determination of the component that causes productivity loss through making cross examinations.

Why reporting tools should it be used?

Each machine stoppage that takes place and each operation that doesn’t conclude appropriately at first shot signify an increase in costs. Lowering costs and increasing productivity are possible through analyzing losses. The 5W1H analyses of the machines’ stoppage and operation losses shape the efforts carried out to prevent the reoccurrence of these losses. For instance, if a malfunction occurs at a machine due to the strap splitting, analyzing the average splitting duration of the strap and changing the strap before it splits would remove the manufacturing loss.

Carrying out the manufacturing operations with the lowest cost is possible via conducting the production operation with the appropriate machine, raw material, operator and mold/device/equipment. Reporting of cycle time, operation error and stoppage durations with machine, operator, shift, product and work order information via cross examinations bears significance for this reason.

Impact of reporting tools on production

It leads in taking the actions that ensure manufacturing operations to be brought closer to perfection as a result of the loss and root cause analyses. Via ensuring that the production and operation are carried out in the most appropriate machine, operator, raw material and mold/device in line with the analyses, lowest-cost manufacturing is realized. It provides the opportunity for the most appropriate data to be used in order for the cost calculation to be made accurately and updating cycle times through the analysis of completed cycle times.

What does operator dashboard module do?

The operator dashboard module is a software product that provides the operators with instant information on production. It ensures that operators working at manufacturing have information on produced amounts, scrap amounts, stoppage information and machine effectiveness during their working hours.

Why operator dashboard should be used?

The operator interface module enables automatic signal collection from machines, measurement of stoppage durations and the operators to enter scrap details to the system while removing the necessity of pen and paper. It facilitates traceability via ensuring that data are gathered at one place.

In addition, while giving information regarding current and past production to operators, it provides performed production information in relation to the carried out work orders. Moreover, it decreases the possibility of machine malfunctions and overproduction, as well as giving information on the future of production and machines. When machines crash, it speeds up technician response and this way, decreases stoppage duration, hence leading to an increase in OEE.

Impact of operator dashboard module on production

This module will indisputably increase the production team’s awareness on the current production status. The quality of production is calculated and shown to the operator. These information will ensure that business owners increase performance that will result in increased manufacturing effectiveness. Furthermore, it saves the operators from pen and paper via removing any possibility of mistakes.

What does incident module do?

With the incident module, users can send reports that are generated in ProManage to desired individuals. In addition, notifications are sent to certain individuals via the incident module when a certain incident takes place on a machine.

Why incident module should be used?

With ProManage’s reporting tools, users can create any graphic or Excel document and send them to specified individuals. After the necessary report is created, the user can send it to a person or persons when desired. The time of the report that will be sent can be changed with various options. The amount of reports and to whom they are required to be sent can totally be adjusted. This way, the system automatically provides its users with the information they want regarding machines via emails or text messages. In addition, it draws its users’ attention via sending notifications from its mobile application.

In cases when a certain action takes place on a machine, the incident module will send an e-mail or SMS to defined individuals. Therefore, for instance, when a technician is called, the response duration to a machine will be speeded up and the machine will be brought to a functioning status. This feature is used for attracting the attention of the authorized individuals when unplanned situations unfold at machines.

Impact of incident module on production

The reports that are sent to the individuals include information concerning production and machines. The structure of the report could be altered in line with the information it should contain. Thus, production responsible will have the opportunity of making analysis over the reports that are generated regarding past information of the machines.

The incident module is triggered when an unplanned action takes place at a machine. For instance, when machines break down, the incident module will be triggered to notify a team of technicians. This accelerates the intervention duration of the technicians to the machines. Moreover, if the technician doesn’t arrive at the machine after a certain predetermined period of time, a separate incident module can be triggered to the technician manager. It’s important to notify authorized individuals in order to ensure that machines are in a functioning status.

ProManage users can track their machines’ statuses from their smart phones. Notifications will be sent to users from the ProManage Mobile Application. This way, users will be informed on their manufacturing statuses 24/7.

Advanced incident module with ProGuard

ProGuard ensures operations to continue according to business rules.