Manual performance tracking was cumbersome in a company stretched across 11 manufacturing plants. Find out how OpteBiz helped this business integrate all 11 locations using a single server to provide real-time production monitoring.

OpteBiz Door Case Study
01
Overview

The company is a pioneer of labeling and packaging materials. Among multiple items, they manufacture different dimension paper rolls for packaging and labeling.

02
Old Process Pain Points

A lot of manual effort was needed to maintain constant output. Also, machine data was supposed to be captured in real-time to have correct production charts, but produced materials were too numerous to use bar codes.

03
Ignition SCADA Approach

An MES application was designed and developed using Ignition for real-time production monitoring.

04
OpteBiz Advantage

OpteBiz achieved a 2% reduction in downtime, 10% improvement in processing throughput, and helped the client achieve a paperless environment

Overview:

The company is a pioneer of labeling and packaging materials. Among multiple items, they manufacture different dimension paper rolls for packaging and labeling. They needed to integrate their 11 manufacturing plants that produce this product into one, using an efficient MES solution. By doing this, they intended to remotely monitor all 11 plants from a single platform and integrate them into their existing ERP system.

A wider roll, called “bulk roll,” is used as the raw material for production. This roll is cut into multiple smaller rolls called “slit rolls.” Work Orders are lined up in ERP, for shift-wise execution based on their priorities. One work order may contain slit rolls of multiple widths. To reduce material waste – multiple work orders are grouped to consume the entire bulk roll. Produced material, in the form of slit rolls, is assigned a unique number for tracking and moved to the designated location for packaging and shipping.

Old Process Pain Points:

In their current process, performance tracking of individual machines from a single location was cumbersome. Parameters such as individual machine runtime, downtime, the reason for downtime, length of individually-produced rolls, scraps from both raw and produced material, etc. were not being captured efficiently. A legacy system was already in place, but it was not efficient enough to meet the requirements. A lot of manual effort was needed to maintain constant output. Also, machine data was supposed to be captured in real-time to have correct production charts, but produced materials were too numerous to use bar codes.

Ignition SCADA Approach:

Ignition was used as the SCADA to take care of all the above requirements and work in sync with the individual, real-time production processes. An MES application was designed and developed using Ignition for real-time production monitoring. All 11 locations were integrated using a single server. The handshake with the ERP was done efficiently and the client was very impressed with the integration and performance of the system.

OpteBiz Advantage:

OpteBiz achieved a 2% reduction in downtime, 10% improvement in processing throughput, and helped the client achieve a paperless environment, which results in a large cost savings and an increase in flexibility.

OpteBiz is incorporated with an objective of offering consulting services & technology integration solutions that optimize operational performance in manufacturing space.

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