PRODUCTION
Software Systems for Production
INTEGRATED SYSTEMS
Plan and manage production efficiently with APS and MES solutions!
Senior Software’s advanced production systems connect and optimize factory flows, providing transparency and efficiency at every stage of the process. Integrated solutions collect and analyze data in real time, allowing for fast and flexible interventions, for the production of high-quality goods at low costs.
The APS system is a tool for modeling and testing production scenarios before they are put into practice. The software solution is frequently used together with the MES system, responsible for executing the production plans generated by the APS.
20 %
increase in factory productivity60 %
reduction in planningtime
ADVANCED SOFTWARE SOLUTIONS
Challenges solved with factory automation systems
APS and MES systems for manufacturing improve overall efficiency and successfully solve numerous operational challenges. Among the most significant improvements are the complete automation of tasks, which also ensures accurate and real-time monitoring of all resources within the organization. These systems significantly contribute to reducing errors, minimizing risks and increasing quality.
Planning made in Excel, on short time intervals
Unplanned cost increase
Inability to test planning scenarios
Excessive planning process duration
Inefficient planning of material requirements
Equipment downtime
Lack of connection between machines, devices, people and processes
Lack of control in production activity
By implementing MES and APS, Flexibil has achieved much better management of raw materials, production capacity, which has implicitly led to increased productivity and profitability. We have real-time control over all production flows and efficient planning of each operation. Another important benefit is the fact that we can control very well the productivity of each person, the employees being paid according to the volume and quality of the products made.
Advanced Planning and Scheduling
APS - production planning and scheduling system
APS shows you what to produce, when to produce, on what equipment and with what resources. The system uses advanced computational algorithms that help balance production capacity with demand, to generate feasible production schedules.
- Plan production in just a few tens of seconds
- Gain immediate access to information regarding production status
- Evaluate multiple scheduling scenarios in just a few minutes
- Instantly identify areas that require additional resources
- Quickly replan in case of unforeseen events
- Schedule production while taking forecasted inventory into account
Manufacturing execution system
MES - Production Management System
The MES solution manages and controls the entire production process, from the moment the order is launched until the finished product is ready, in order to optimize all activities and resources in the production process. The system allows real-time visualization of the entire factory, so that you can follow the production progress, productivity and efficiency of the resources involved at any time.
- Reduce material waste and efficiently manage available stocks
- Improve product quality by constantly monitoring processes
- Get complete traceability at every stage of the production process
- Interconnect and synchronize all equipment and machines in the factory
- Improve decision-making through detailed performance analyses
- Minimize downtime and increase employee productivity
What customers say
De Coltesti reduced the working time dedicated to preparing orders by 40%
“The MES solution has helped us to simplify things a lot, eliminate paper from all production processes and reduce costs. Including the sales process, preparation and sending of products to the customer, involves considerably shorter times, and the risk of quantity or batch errors has been eliminated.”
APS & MES
Immediate benefits of APS and MES integration
The integration of APS (Advanced Planning and Scheduling) and MES (Manufacturing Execution System) systems brings significant advantages in the management of production processes. This combination of interconnected technological solutions allows for the optimization of operational flows, improved reaction to changes in production and cost reduction:
Production Planning Optimization
Improved reaction
capacity
Reduce storage
costs
Production KPI
Evaluate the efficiency of factory operations and optimize production processes
The MES system offers an extensive range of KPIs for monitoring and improving production processes, covering various aspects, from product quality and material usage, to equipment maintenance and operator performance.
Ensure consistent product quality and make quick decisions based on real-time data. The Quality Dashboard in the MES solution provides complete visibility into defects and deviations, supporting continuous improvement of production processes.
- Instantly detect defects that occur in the production process.
- Quickly identify defect types, their frequency and the affected products or batches.
- Represent the evolution of defects through intuitive, easy-to-interpret control charts.
- Immediately signal any deviation from quality standards, allowing for quick and efficient interventions.
- Provides access to real-time updated data, which supports quick decision-making and the correct implementation of corrective actions.
The Materials Dashboard in the MES solution provides essential data for the efficient management of material flows and for preventing production interruptions.
- Monitors the availability of materials in real time, both at the machine and work center level.
- Provides relevant information for the rapid identification of material shortage situations and the prevention of unplanned shutdowns.
- Analyzes defects associated with materials and the production process, with distribution by defect types and specific products.
- Facilitates the rapid identification of causes of non-conformities and supports the implementation of corrective measures.
- Integrates control charts that allow quality tracking for each order and product, providing a clear picture of the evolution of the process.
- Supports continuous optimization of processes, reduction of losses caused by defects and increased operational efficiency.
Provides a clear perspective on the performance of maintenance activities, helping to balance preventive and corrective interventions. The Maintenance Dashboard in the MES solution allows detailed monitoring of operations and supports continuous optimization of equipment availability.
- Efficiently compares the time allocated to preventive (planned) maintenance with that required for corrective (unplanned) interventions.
- Monitors essential indicators such as TTWR (Time to Work Request), the evolution of maintenance orders and the frequency of shutdowns for specific causes.
- Quickly identifies the main reasons for equipment failure, providing support for making corrective decisions.
- Provides a clear picture of the impact of maintenance on production, through intuitive dashboards and real-time analysis.
- Contributes to reducing downtime, preventing major defects and optimizing maintenance programs.
- Supports increasing operational efficiency and extending the life of equipment.
Provides a detailed analysis of equipment downtime, providing visibility into causes at both operator and plant level. The Reason for Downtime dashboard in the MES solution helps companies quickly identify the main sources that generate production interruptions.
- Monitor equipment downtime in real time and analyze their causes at multiple levels - operator, line, work center or plant.
- Quickly highlights the 5 most common reasons for downtime, providing a clear focus for corrective actions.
- Provides accurate data to understand the impact of each reason on production continuity.
- Allows prioritization of interventions and efficient allocation of resources depending on the impact of downtime.
- Supports the reduction of downtime and optimization of processes by eliminating recurring causes.
- Contributes to increasing operational efficiency, better utilization of equipment and improving productivity.
The OEE (Overall Equipment Efficiency) dashboard provides a complete and accurate analysis of overall equipment efficiency, helping companies understand and improve operational performance over time.
- Analyzes equipment efficiency on a monthly and annual basis, providing an overview of performance.
- Allows visualization of daily OEE values for each machine, facilitating real-time performance monitoring.
- Provides details on the three OEE components - availability, performance and quality - to quickly identify areas with potential for improvement.
- Helps quickly detect operational deficiencies that affect productivity.
- Supports data-driven decision-making to optimize equipment utilization and reduce waste.
- Contributes to increasing productivity and maximizing resource utilization.
Monitors operator activity in real time and provides a detailed analysis of how working time is used. The Operator Dashboard in the MES solution supports efficiency improvement through a clear understanding of each operator’s contribution to the production process.
- Analyzes the time allocated by operators for direct, indirect activities and idle periods.
- Allows monitoring of times per machine, order and item, providing a detailed perspective on resource utilization.
- Compares planned time with actual working time, quickly identifying deviations and inefficiencies.
- Provides essential data for optimizing operator allocation and balancing workloads.
- Supports data-based decision making to increase operational efficiency and reduce waste.
Monitors key equipment indicators to support proactive and optimal management of production equipment. The Available Equipment Dashboard in the MES solution helps prevent downtime and maximize equipment performance.
- Tracks machine availability and essential parameters such as MDT (Mean Downtime) and MTBF (Mean Time Between Failures).
- Provides accurate information for early identification of problems and implementation of preventive measures.
- Supports the reduction of downtime through constant monitoring and effective interventions.
- Contributes to extending the life of equipment by proactively managing their condition.
- Optimizes overall production performance by maintaining equipment in optimal operating condition.
It is an essential interface for the continuous collection and monitoring of quality data, providing an accurate assessment of the performance of processes and products. The Data Collection Dashboard in the MES solution ensures transparency and complete control over quality on the production line.
- Collects real-time data directly from the production line to quickly identify deviations from established standards.
- Monitors critical parameters to ensure constant compliance with customer specifications and applicable regulations.
- Enables immediate implementation of corrective measures based on accurate and up-to-date information.
- Organizes data and displays it through intuitive reports and graphs, providing a clear visualization of the quality status.
- Supports continuous evaluation and improvement of processes throughout the production flow.
COMPLETE PRODUCTION SOLUTIONS
Best-in-class systems for the manufacturing companies
Interconnected software systems turn your production unit into an intelligent factory. You can achieve production automation and factory digitization, from designing the concept to launching the product on the market.
