GUARDUS MES

www.guardus.de

The long-time experience in industrial

manufacturing has made GUARDUS

Solutions AG a household name in

Quality and Production Management.

The core of the internationally

renowned enterprise is based on the

Manufacturing Execution System

GUARDUS MES.

This software solution represents the

interface between the operational part and

the global PPS and ERP solutions. The

GUARDUS solutions belong to the leading

systems in this field being implemented at

over 150 companies from 22 countries.

GUARDUS MES

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GUARDUS MES is a homogeneous solutionfor the continuous collection, visualization,and monitoring of all the product and processdata along the value-adding chain.

All the requirements coming from qualityand production management (CAQ, PDA,MDA, TRA & KPI) will be fulfilled by the Ma-nufacturing Execution System of GUARDUS in a central application. Not only quality and production, but also the product develop-ment as well as customer and suppliers’ relationships are part of GUARDUS MES.

The answer to this question can be foundin the mere philosophy of the company:sovereignty, passion, and loyalty.

Sovereignty, for GUARDUS, means to beable to stand on its own and to decide onall the aspects regarding human relations,technology, and finances for itself. Thisfreedom also represents the basis of oursolutions.

Passion, creativity, and the courage tobe different – these are the principles ofour visions. They give our customers thecertainty that by using GUARDUS MESthey are always one step ahead.

Loyalty and sustainability are notonly promises made to the customers.They represent the highest expressionof GUARDUS’ character. Therefore, aGUARDUS solution represents morethan only products and services. It isthe promise of facing existing and futurechallenges.

MDA PDA

TRA

KPI

CAQ + More = MES

The Courage to be Different

To develop, bring to the market, andimplement innovative ManufacturingExecution Systems (MES) and ComputerAided Quality Assurance (CAQ) solutionsare the core business area of GUARDUSSolutions AG.

Our solution GUARDUS MES guaranteesthe highest flexibility and individuality.When the standard software applicationGUARDUS MES is implemented at thecustomer’s location in situ, it becomes‘their’ solution which generates significantbenefits and enthusiasm. But how canwe achieve all this? How can we inspireenthusiasm expressed by long-timecustomer relations?

MES

PHILOSOPHY

CAQ

„GUARDUS steht für Innovation und setzt heute um, was unsere Kunden morgen brauchen.“

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clearly defined tasks from which importantintegration aspects derive.

How it works The ERP and MES software solutions share operational data such as orders, incoming goods, production bill of materials, production orders or resources. The PLM and MES application share drawings, product and characteristic data, whereas the PLM and ERP systems share bill of materials and other flow charts.

� Highly Flexible Software via Design Function and Change Management

� High Ability of Integration into the IT Landscape via Interfaces

� Comprehensive Functionality for Quality and Production Management

� Software Quality and Validation Capability

� Modularity and Scalability

� Multilingualism (Unicode) and Implementation in 22 Countries

GUARDUS is innovation, implementing today what business needs tomorrow.

Standard

In today’s competitive environment,“process velocity” represents a key factorin organizational strategy. Modern lean andother efficiency methodologies offer toolsto accelerate and add value to every stepwithin the production chain and within theorganization. A project and process orien-tation is meant to break down the barriersbetween business operations.

In this context of high velocity, informationflows are often the limiters to the achieve-ment of higher organizational success. Inthe future, better information technologywill focus on better security, increasedtransparency, and full integration between

databases and organizational resources.Considering the IT landscape of the future,in which context does an MES applicationcoexist with the other information systems?Based on the history of consolidation inERP systems, GUARDUS foresaw that ITprocesses on the shop floor would alsobe combined within one MES solution.The IT landscape of the future will alsoinclude product development and it willbe divided into three key elements ofa manufacturing enterprise: BusinessPlanning and Logistics (ERP), Design andDevelopment (PLM), as well as Manufactu-ring, Operating and Control (MES). Eachof these segments is characterized by

The IT Landscape of the Future

StrategicPositioning

of MES

MESPLM

ERP

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GUARDUS. When directly capturingdata on the shop floor, GUARDUS MESalso supports several standards used bynumerous machine manufacturers. Theseinclude assembly lines and productionfacilities as well as measuring machines,hand measurement equipment, testand vision systems. All parameters andinspection results consist of high qualityand are available in real-time. Moreover,automated workflows and escalationmechanisms within GUARDUS MESconnect all communication partnersand thus, provide an efficient use of theextensive basic data.

GUARDUS MES represents a centralcomputerized solution for organizationsfocused on an international clientele.Its goal is to provide value addinginformation all along the production chainand to facilitate the automation of allmanufacturing processes. Our solutionsare based on an integrated technologyfor the process-oriented capture,visualization, and monitoring of all qualityand production data. Every aspect of theproduction life cycle is integrated intoone system: both quality and productionfactors are captured via machine andmanual data acquisition to provide producttraceability, fully managed maintenance of

GUARDUS MES – One for All, and All for One

equipment, and production and qualityperformance indicators. The basis forthis extensive pool of knowledge is theautomated and economic integration toboth upstream and downstream systems.GUARDUS has more than 20 years ofexperience in connecting ERP and PPSapplications. A standard interface, withpre-configured mappings of data fields,has been designed for more than 20business applications. These can be –depending on the customer’s situation –simple, flexible and above all, version andrelease unrelated. Not only the standardsystems such as SAP, but also thecustomers’ software can be connected to

� ERP/PPS Integration

� SAP Integration

� PLM/CAD Integration

� Measuring and Inspection Equipment Integration

� Process Parameter of Facilities

� Machine Connectivity

� Integration of Mail and Calendar Functionalities

� Office Programs

� Internet Portals

Integration

STRUCTURE

ShopfloorERP

PLM/CAD

MES/CAQ

MeasuringEquipment

Test EquimentMachines

SpecificationsDocumentsDrawings

SAP

Infor

Navision


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GUARDUS Solutions AG customers arefocused on discrete manufacturing; theyare often market leaders in their field,producing their products all over the world.Their challenges: to develop internationalprojects on-time and on-budget, to reducelead-times and stocks, to maximizequality and customer satisfaction. For thisdifficult undertaking, they use GUARDUSMES – a computerized solution for

the management and efficient controlof decentralized production units andorganizational structures.

GUARDUS’ perfectly tailoredmanufacturing execution software (MES)supports the individual processes ofits customers, such as: automotive,electronics, aerospace, plastics andmedical device industries. In all these

segments, GUARDUS has providedextensive ‘know-how’ – not only coveringall production technologies and methods,but also interrelating organizationprocesses and industry norms.

GUARDUS solutions inspire enthusiasm in the worldat home in your industry.

Using GUARDUS MES Solutions

Automotive Electronics Aerospace Plastics AssemblyMedicalTechnology

Metal- working

Roll Manufacturing

„We know the fine nuances that make the difference

in your industry.“

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Extensive Range of Services

GUARDUS Solutions AG focuses onthe individuality of each customer,not only in designing the appropriatesoftware solution, but also in offeringtailored customer support. The rangeof services begins with the selection ofthe right product and the elaboration ofextensive analyses of the current situation.Through structured project management,GUARDUS guarantees the efficientimplementation – from data transferup to the customization of functionsand interfaces based on customerrequirements – and a constant control

of costs, time, and resources so that theproject may be implemented accordingto the plan. The start-up of the softwaresolution is also proof of GUARDUS’project expertise for decades. Go live androll-out strategies tested in the practicewill ensure that the production will not beaffected at all. Moreover, GUARDUS hasa long history of validation competence inthe form of customized service packagesincluded in client validation projects.

� Consulting

� Implementation Support

� Project Management

� Training

� Support

� Validation Support

COMPETENCE

Projekt

Project

Prozesse

ProductionFunctions

Interfaces

ITSoftware- Development

Prozesse

Processes

Prozesse

Quality


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The core to GUARDUS Solutions AG’sphilosophy is the notion of providinghorizontal support for all quality andproduction relevant processes along thevalue chain. This is reflected not only in itsstrategic orientation, but also in each

Process Focus and Functional Diversity

component of GUARDUS MES. All mo-dules are provided with extensive and con-sistent basic functions covering a closed loop (Plan-Do-Check-Act). Each element can also be implemented independently from other GUARDUS components.

Thus, enterprises can start theimplementation with the modulesadding the greatest value from the start.Afterwards, they can progressively addnew functions.

Graphical user interfaces can be adaptedto the users’ workplaces, thus allowingthe efficient use of the versatile functionsprovided by GUARDUS MES. The MESapplication focuses not only on theprocess orientation, but also on thecurrent production processes. Therefore,each user is provided only with thosescreen forms and functions necessaryto accomplish a particular activity. Withthe GUARDUS Designer, the end-users‘own software administrator implementsthe desired modifications of the graphicalinterfaces rapidly and with ease. Thesemodifications will be stored in theGUARDUS MES database and versionmanagement will keep an image of everyrevision for future reference.

We adapt ourselves to your requirements because the holistic customer orientation is GUARDUS’ everyday life.

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� APQP Requirements

� Project Templates

� Online Planning Board for Projects (Gantt)

� Central Administration of All Project Documents

� Transparency of „in time“ and „in budget“

� Integration Action Management

� Integration FMEA

1.1 Project Management

The Project Management module inGUARDUS MES has the central task ofsupporting and developing the managementof projects in a more efficient way. Projectscan be defined either according to thespecifications of the APQP or according tothe company-specific requirements.

The target is to automatically provide theresponsible employee with all the project related information (actions, responsibilities, deadlines, documents) and to use an early warning system via the monitoring functions.

Due to traffic-light functions, the usercan visualise all the activities, and, at anytime, he/she can obtain a detailed imageof the development and progress of eachproject. The actions that are taken in case ofdeviations can be traced via the GUARDUSMES Action Management.

Moreover, the project can also be easily andclearly visualised and further processed in aGantt chart.

Quality Management

1.1 Project Management

1.2 Initial Sampling

1.3 QM Supply

1.4 QM Production

1.5 Defect Collector Chart

1.6 Complaint Management

1.7 Action Management

1.8 Measuring Equipment Management

1.9 Audit Management

Production Management

2.1 Production Order Management

2.2 Production Data Acquisition

2.3 Machine Data Acquisition

2.4 Production Control

2.5 Maintenance

2.6 Traceability

2.7 Energy Management

2.8 Production Logistics

2.9 Planning/Scheduling (APS)

ProcessManagement

3.1 KPI Cockpit

3.2 Workflow Management

3.3 Document Administration

3.4 GUARDUS Designer

3.5 GUARDipedia

3.6 GUARDUS Apps

Integration

4.1 ERP/PPS Integration

4.2 SAP Integration

4.3 PLM/CAD Integration

4.4 Measuring and Inspection Equipment Integration

4.5 Process Parameter of Facilities

4.6 Machine Connectivity

MODULES


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GUARDUS MES supports the wholeprocess of initial sampling fromplanning and execution through versionmanagement and status administrationup to the inspection report and samplingrelease. To configure content, not only arestandard forms according to VDA 2 andQS 9000 available, but also individualizedforms and requirements can be integratedinto the operation by means of anintegrated report designer.

In case of resampling, the characteristicsthat have already been collected areautomatically used including specifications

such as tolerances, inspection instruc-tions, or measuring equipment. Theintegration of CAD systems and measuringequipment also reduces the samplingeffort considerably. The result of the initialsampling is subsequently included inthe inspection planning. This integrationguarantees the compliance and supportof the ISO-chains. Thus, in the goodsincoming inspections, only sampled andreleased products are accepted, andonly inspected parts are manufactured inproduction.

� Status Administration

� Stamp Drawing

� Support for Re-sampling

� Releases and Versioning

� Access to All Documents

� Integration Drawings/CAD

� Integration Inspection Planning

1.2 Initial Sampling

Innovative technology brings standardized functions togetherto provide the perfect solution based on your requirements.

� Inspection Planning

� Goods Receipt Inspection

� Dynamic Modification and Sample Procedures

� Supplier Rating

� Supplier Complaints

� Evaluations

� Integration into Free Defect Collection (Internal Complaint)


The ‘QM Supply’ module controls allthe inspection processes from goodsincoming to production release andsupports the continuous improvementprocess with suppliers.

Intelligent methods dynamically providean optimum supply and product qualitywith the simultaneous optimization of theinspection effort – from inspecting everyitem up to skip-to-stock.

The extensive supplier rating takes intoconsideration not only the delivery quality,but also volume and time compliance.Subjective criteria of analysis such as thecomplaints from the production are alsoincluded in the subsequent reporting.

The analysis are available to alldepartments and provide support topurchasing, quality management, andlogistics in their everyday work.

1.3 QM Supply

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The ‘QM Production’ module supports theefficient planning, execution, and analysisof the in-process inspections, such asintermediate and final tests, laboratoryanalyses, as well as the in-processinspections that are carried out by theoperators at the machine, whereas theuser interface can be adapted specificallyto work environments. The integration ofmeasuring equipment, measuring devices,and manufacturing equipment providesthe necessary efficiency in data collection.

SPC procedures offer support to thestatistical process control. Detailedstatistics and quality performanceindicators constantly provide up to dateinformation about the process stability andproduct quality while the information aboutdefective parts is delivered directly to thePPS/ERP system, securing that only theapproved parts reach the next productionstage.

� Inspection Planning

� In-process Inspection

� SPC Procedures

� Intermediate and Final Inspections

� Inspection Reports/Reject Documents

� Evaluations

� Q Monitor

� Integration Action Management

� Integration „Paperless Repair“


1.4 QM Production

1.5 Defect Collector Chart

The GUARDUS MES ‘Defect CollectorChart’ module supports the directcollection of defects encounteredalong the production chain. Centrallyconfigured check lists supported bydefect catalogues (e.g. according to familyor version inspection plans) representthe basic elements of this module. Anyapproved changes in these lists areimmediately available online at everyworkplace.

The simple user interface can beconfigured to collect data either with theusual keyboard and mouse or throughtouch screen technology.

You can make a remark by simply clicking.In order to improve support productionemployees, defect frequency is graphicallydisplayed and documents (e.g. drawings)are available at the push of a button.When violations do occur, the responsibleemployee is automatically informed sothat an intervention or a correction of thedeviation can be executed promptly. Atthe end of the shift or order, performanceindicators concerning failure rates, criticalerrors per part, orders, and time rangeswill be transferred to the PPS/ERP systemand they can be visualized online with afew mouse clicks.

� Intuitive Handling

� Touch Screen

� Display of Documents

� Online Evaluations


MODULES


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Defect prevention with GUARDUS MESfrom 100 to zero in record time.

The ‘Complaint Management’ moduleof GUARDUS MES enables the efficientprocessing and tracking of complaints(CAPA) and returns in a central system.

Internal and external complaints arecollected and monitored globally, from thedepartment of sales, quality assurance,production and development up todistant locations via the Internet. Notonly complaint reports, 8D reports, andresults (including defect images) of theoperation, but also the commercial andtechnical decisions, as well as complaint

costs, actions, and deadlines will beadministered here. Thus, the customer isalways informed about the latest status ofhis complaint.

These quality data offer concreteinformation about the product qualityand is included together with the supplierrating into development and productionplanning.

1.6 Complaint Management

� Operation Processing

� Result Data and Defect Images

� Status Administration

� Complaint Costs

� Evaluations

� Integration into Traceability

� 8D Report

The ‘Action Management’ module ofGUARDUS MES actively supports thecontinuous improvement process (CIP).

It is a central collecting and coordinationcentre and, therefore, all the actions fromthe areas CAQ, PDA, and MDA suchas audits, goods incoming inspections,production defects and process violations,as well as 8D-reports, customer andsupplier complaints are collected here.

Defined actions and to-do lists areautomatically scheduled and set forreview. Open and overdue actions areimmediately sent to processing.

This generates a database of knowledgethat provides all the users with targetedinformation which represents the basis forimprovement actions (CAPA) and lessonslearned.

1.7 Action Management

� Action Definition

� To-Do List and Resubmission

� Deadline Monitoring and Workflows

� E-Mail Integration

� Escalation Management

� Evidence of Effectiveness

� Evaluations

� Development of a Knowledge Database

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The ‘Measuring Equipment Management’module of GUARDUS MES guaranteesthe regular monitoring and calibration ofthe measuring equipment that is used formanufacturing and production control andtakes care of the norm conformity of themeasuring equipment capability.

Organized according to types andgroups, the whole usage and calibrationhistory for the inspection planning,maintenance, and evaluation is stored onthe corresponding identification card ofthe measuring equipment. The special

advantage: The inspection intervals canbe better adapted to the actual state of themeasuring equipment in order to reducethe calibration effort.

Through the integration of the measuringequipment database into the inspectionscarried out in the production, GUARDUSsupports the obligation to prove whichmeasuring equipment was actually usedand provides the immediate measuringequipment traceability.

1.8 Measuring Equipment Management

� Measuring Equipment Management

� Measuring Equipment Master Cards

� Inspection Intervals

� Booking History

� Schedule Lists

� Measuring Equipment Calibration

� Measuring Equipment Capability

� Integration into Inspection Planning and Data Collection

� Usage Certificate

1.9 Audit Management

Internal and external audits of processes,systems, and products are planned,executed, and monitored with the ‘AuditManagement’ module of GUARDUS MES.

Each audit can be administered accordingto deadline, audit type, topic, supplier, audited area, or responsible auditor.

Basic question catalogues, to whichspecific customer demands can be addedat any time, enable efficient planning.

The auditors are provided with comfor-table planning and escalation tools for the deadline monitoring and rescheduling.

Evaluations can be called via the archive;the auditor will find here important infor-mation about the previous weak pointsand the initiated actions.

� Audit Planning

� Qualification Matrix

� Norm-related and Specific Question Catalogues

� Audit Preparation and Execution

� Audit Evaluation and Reports

� Support at External Audits

� Integration into Action Management

� Audit Evaluation

MODULES



GUARDUS keeps strategy in sightour customer determines speed and approach.

The “Production Order Management” ofGUARDUS MES takes over the productionorders from the ERP system and insuresimpeccable and up-to-date administration.The basis for this is a multitude of masterdata and parameters that are eitherprovided by the ERP system or directlysupplemented in GUARDUS MES.

If the business data is not detailedenough for the required productiontransparency, further information can bestored in production order management.Thus, GUARDUS MES supports theadministration of operations, as well ascontrol parameters, production resources,bills of materials, and valid documents.

2.1 Production Order Management

� Order Data with Bill of Materials, Production Resources, Documents etc.

� Manual Supplement of Work Processes/Operations

� Order Data Transfer from the ERP System

� Generation of Additional Orders (e.g. for Rework)

� Order Release and Locking

� Calculation of Payroll Basic Data

� Order Confirmation to the ERP System

� Payroll Data Confirmation to the ERP System or Payroll System

� Operation Calendar

Besides the display of dispatchedorders, the ‘production data acquisition’of GUARDUS MES reports not onlyquantities, times, inspection results,releases, or events in real-time, but alsoall the information about the personnelsigning in and out.

This information can refer to persons,teams, or shifts. The input dialogue boxesfor the operator can be optimally setup onthe basis of standards. The use of barcodescanners, touch screens, etc. is activelysupported. The integration of GUARDUS

MES QM Production provides for thenecessary self-control of the operatorsvia SPC control charts and in-processinspection plans.

The target: An interface for all therelevant entries.

2.2 Production Data Acquisition (PDA)

� Personnel Log on and Log off

� Usage by Several Users and for Multiple Machinery

� Order Log on and Log off

� Time Data Collection

� Quantity Information

� Display of Documents

� Printing of Accompanying Documents/Labels

� Integration of Quality Data Collection (QM Production)

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Machine data, such as quantities,statuses, delay reasons, as well as processparameters and energy consumptionare very important for the planning andcontrol of optimum use of resources. Theefficient and complete collection of relevantinformation in GUARDUS MES is providedby an intelligent standard interfaces. Simple software dialogues ensure a quick entry of data.

For the online monitoring, the user usesthe integrated plant layout or the automaticalarm mechanisms of GUARDUS MES.Further graphical tools such as delayreasons pareto, runtime diagram, OEEcockpit, or machine logbook offer anoptimum support for the discussions in theshift and analyses. These methods can beapplied not only for the machines, but alsofor the lines and manual workplaces.

2.3 Machine Data Acquisition (MDA)

� Delay Reasons

� Quantity Information

� Time Type Information

� Machine Status Information

� Energy Consumption

� Process Parameters

� Administration Production Hierarchy

� Plant Layout

� Production Cockpit

� Runtime Diagram

� Visualisation in the KPI Cockpit

2.4 Production Control

The ‘Production Control’ of GUARDUS MES ensures an efficient planning of the order sequence. All the relevant ERP orders are transferred to the system via intelligent standard interfaces and are planned by me-ans of graphical and mathematical support. Of course, the manual intervention via drag & drop is also possible at any time. For the purpose of creating the best plan, the user is also able to work in a scenario mode in which potential conflicts are automati-cally visualised and the plan modifications are recorded in a ‘logbook’ until they are actively released.

Conceived as a pragmatic tool, the graphical planning table of GUARDUS MES offers support via clear representations in every area. The real situation of the machi-ne status as well as the current deadline or the order progress are visualised online.

� Graphical Scheduler

� Order Splitting

� Combining of Orders

� Online Visualisation of Confirmations (Order Progress)

� Information System (Workflow) in Case of Deviations from the Production Planning

� Dispatch of Manufacturing Orders to Production Machines

� Sequence Planning for Dispatched Orders

MODULES



The basic element of the GUARDUS MES“Maintenance” module is the basic data.The machines, production units, or toolsthat have to be submitted to maintenanceworks are administered in a master cardvia a user-friendly interface. Moreover,the corresponding spare part lists andmaintenance plans are also integrated.The actual maintenance can becoordinated by means of a maintenanceplan and its versions. Here, theadministrator plans the concretemaintenance measures either in a cyclicalway or depending on the condition or

event. Individual check lists, spare partlists, and bill of materials describethe tasks that have to be performed indetail and represent the basis for themaintenance orders.

As soon as an order is reported as“finished”, the corresponding maintenanceproposal is set to the status “completed”.For detailed feedback, the usersubsequently issues a maintenance andrepair report and, in case of externalactivities, he/she enters the actuallyincurred costs.

2.5 Maintenance

� Maintenance Plans

� Bill of Materials and Spare Part Lists

� Checklists

� Maintenance and Repair Orders

� Cost Transparency


Individualisation and flexibility have the highest priorityin quality and production management.

The ‘Traceability’ module of GUARDUShandles all traceability via batch,lot, box and serial number recording.

If a defect is discovered at any step, thecomplete production process can betraced back through every manufacturingstep and along the logistic chain down tothe individual suppliers in order to identifythe potential responsible entities(bottom-up).

In the other direction, GUARDUStraceability quickly shows eachcomponents were processed in whichcompleted product (top-down). Qualitydocumentation and release reports areavailable online and on demand.

Combined with the QM Productionmodule, quality data (e.g. characteristics,tolerances and collected measured values)can also be automatically displayed onlinefor the manufactured products.

2.6 Traceability

� Collection of Batch, Box and Serial No., etc.

� Access to Bill of Materials

� Complete Product Documentation (Device History)

� Top-down and Bottom-up Researches

� Online Access to Inspection Results and Order Data

� Use of Scanners (Barcode, 2D Matrix)

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The GUARDUS MES „Energy Manage-ment“ module offers significant support to industrial companies that have the task to design their production processes in a sustainable and environmentally sound way. The basis for this is the so-called direct energy consumption measurement, that is, the integrated collection, connec-tion, and analysis of product, process, and energy data per manufacturing equipment and order.

Due to the holistic data display, energy-related indicators can be calculated permanufactured product quantity at the

push of a button. The online evaluation ofthese indicators can be quickly and easilyvisualised via the energy consumptionmonitor. Since the conditions for theexemption from the surcharge of theGerman Renewable Energy Act aresevere, for the industrial companies, it isincreasingly more important to provideevidence of energy savings throughenergy efficiency indicators. For this,not only must an energy managementsystem be introduced according to theISO 50001, but also a correspondingcontinuous improvement process mustbe implemented by means of the PDCAmethod.

2.7 Energy Management

� Master Data per Energy Counter

� Assignment of Energy Counters to Production Units

� Automatic Energy Data Collection (EDC)

� Manual Collection of Consumed Quantities and Counter Values

� Analysis, Evaluation and Calculation of Energy Consumption

� Performance Indicators per Product, Machine and Production Order

� Transfer of Order Data from the ERP

� Technical Connection of Energy Counters

The “Production Logistics” module of GUARDUS MES guarantees the highest efficiency for the material flow. The main element is the control of the intra-logistic processes on the basis of actual data.

Synchronised with the current operations, the right material will be supplied or remo-ved to/from the machine/production unit at the right moment for each manufacturing order. This is valid not only for raw materi-als, but also for produced material stocks on the shopfloor – the so-called ‘Work in Process’ (WIP). The processing of in-time logistic information makes sure that the interlinked operations can be started at

the right moment and the whole order can be executed in-time.

The seamless integration into the opera-tional business world as well the surroun-ding systems of transport and warehouse management allows for the necessary process safety. Depending on the contai-ner unit and active production cycle, the machines and production units determine the transport frequency of the supply as well as the removal of material, thereby improving the agility in the production.

2.8 Production Logistics

� Online Information for the Smooth Calculation of the Material Demand

� Flexible Control of the Material Request via Various Parameters

� Comfortable Integration Procedures for the Connection of the Surrounding Systems of Transport and Warehouse Management

� Seamless Communication Flows by Using Mobile Devices

� The Most Modern Techniques of Collecting the Ware – Barcode, Data Matrix Code or Chip Card and RFID

� Intuitive Transport Order Board for the Efficient Execution of Pick-up Orders

MODULES



Safe decisions require completeand continuous informationen.

Based on the VDMA standard sheet66412 and ISO/DIS 22400-2, GUARDUSKPI cockpit provides Key PerformanceIndicators (KPIs) for each control level. TheMES indicators are available at every levelin real-time, whether top management,department heads, or shop floor workers,thus delivering detailed insights into thecurrent quality situation. The KPI cockpitcontains online indicators about machines,products, processes, and suppliers thatserve for the direct process control, aswell as KPI and trend analyses for monthlyand quarterly reporting.

The KPI cockpit also contains theGUARDUS KPI methodology for the rootcause analysis. Via drill down functions,this allows the quick analysis of weakpoints in products, processes, and qualityas well as problems with suppliers, theimmediate intervention with correctiveactions and the possibility of verifying theeffectiveness of those actions.

3.1 KPI Cockpit

� Quality and Production Performance Indicators

� OEE, Quality Rate, Performance Degree, Availability

� MES Performance Indicators (ISO/DIS 22400-2)

� Traffic-light Function

� Drill-Down

� Export Functions and Reports

� KPI Methodology for Root Cause Analysis

� Effect Models (Standard Sheet 66412)

3.2 Workflow Management

By means of the ‘Workflow Management’module of GUARDUS, the informationabout any events, such as toleranceviolation, machine malfunction, exceededdeadlines, is quickly and easily automated.Via the workflow settings, processes canbe standardized and monitored in anefficient way.

In addition to the free configuration ofevents, the user can also have access to100 pre-defined standard processes thathe/she can individually adapt within a fewclicks.

The ‘Workflow Management’ belongs tothe system basis of GUARDUS MES and isavailable in all modules. This functionalityis generically conceived and can beapplied to all product and process datawithin GUARDUS database.

� Free Definition of Alarms, Rules and Conditions

� Specification of Receiver: Related to Persons, Groups or Station

� Automatic Sending of E-Mails

� Over 100 Predefined Workflows

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The ‘Document Management’ moduleprovides the right documents and contentfor every task related to quality andproduction management. All the necessa-ry current information can be retrieved with“a simple click”.

During the quality inspection in goodsincoming and outgoing and in theproduction, additional documents suchas detailed work instructions, drawings

or pictures of products also increase theefficiency and safety of the inspections.

In the production, this function allowsthe users to call product data sheets,drawings, setting data, and online toolinformation at their workplace withoutusing paper.

3.3 Document Management

� Filing of Important Documents in the GUARDUS Database

� Access to Documents from Third Party Systems (CAD Systems, Document Management Systems, etc.)

� Assignment of Documents to Different Objects (Article, Order, Inspection, Complaint, etc.)

� Structuring of Documents According to Freely Defined Catalogues (Document Classification)

� Various File Formats (XLS, PDF, DOC, JPG, TIF, AVI etc.)

� Management of Validities, Comments, etc.

By means of the GUARDUS MESDesigner, the graphical interfaces can beadapted to the respective workplace ofthe user in a very flexible way. Thus, eachuser receives only those screen forms andfunctions that he/she really needs for his/her individual activity. This applies notonly to the look and feel of the softwaredialogue boxes, but also to their logic andplausibilities.

Over 1,100 interfaces, the so-calledresources, will be saved and versionedin the database of the MES by theGUARDUS MES Designer, and then theywill be released by means of project

management. The trained user can alsomodify the graphical interfaces. The newlydesigned and update-capable dialogueboxes will then be administered in thecentral database.

Due to this innovative technology, allthe interfaces of the standard softwareGUARDUS MES, whether standard orcustomized screen forms, can be validatedat any time.

3.4 GUARDUS Designer

� Highly Fexible Design of User Dialogues Release-capable

� No Compilation due to Immediately Executable Macro Code

� Integrated Resource (Application) Management

� Integrated Version Management

� Automatic Administration of Functions and Interfaces

� Automatic Evidence of Function Modifications for Revalidations

MODULES



GUARDUS develops standard software solutionsfor sustainable product and process optimization.

This web portal is a central informationsource that allows for selective knowledgetransfer regarding all GUARDUS MESstandard functions – from the transparentmodule overview to ‘tips & tricks’ andto the elaborate resource and fielddescriptions. GUARDipedia represents anonline help and, as such, it can be directlyaccessed from the MES itself. Moreover,the new developed process maps alsooffer a special help.

Its graphical display of the GUARDUS MESprocesses with integrated graphs, flashanimations, as well as linked documentsand descriptions shows the relationsbetween the various modules, functions,

3.5 GUARDipedia

all the fields in the GUARDUS screenforms are linked with the correspondingdescriptions via image maps. If the userclicks on the desired dialogue area, he/she will be directed to the explanations inGUARDipedia.

and data flows in a transparent way, anddeepens the user’s understanding of thesoftware.

Due to an integrated keyword search,the desired topics, functions, resources,or fields can be found quickly. Moreover,

Tipps & Tricks

Our online documentation represents amultilingual interaction tool that is availableall over the world as a comfortable Wiki.

The Business Apps of GUARDUS MESfollow the principle “make it smart” andoffer a completely new form of decision-making and process control to the user that is independent of their location. Their process-oriented operating concept aimsat providing a clearly outlined quantity ofinformation in a simple and quick way andin real-time, or in other words, exactly whenthe employee needs it.

In combination with the modern hardwarecomponents, such as smartphones,phablets, or tablets, the compactassistance programs are adequate fora multitude of quality and production

management tasks, such as the mobileretrieval of performance indicators for aquicker analysis of the cause and impact ofpotential quality and production problems.

Moreover, the GUARDUS MES businessapp kit contains solutions for the mobileproduction monitoring and the efficientsupplier rating. The technological basis isthe so-called MobilePlace of the integratedGUARDUS MES database where all thebusiness apps as well as their access rightsare administered and controlled centrallyand safely, independently of the externalcloud and app infrastructure.

3.6 GUARDUS Apps

� App Administration in the GUARDUS MES Mobile Place

� Administration of Authorizations and Access Rights for Apps

� Free Configuration of Workplaces or Process Models

� Easy Assignment of Apps to Graphical Process Models

� Integrated Release Management for Apps

� Central Administration of Configurations in the GUARDUS MES Database

PHILOSOPHIE

20

Technical Philosophy

GUARDUS’ technology is based on thefact that all the screen forms can beindividually adapted to the work processes.Procurement managers, personnelresponsible for production and quality aswell as service employees will always beprovided with the right functions in the rightform and at the right moment.

This flexibility simplifies the applicationand increases the employees’ acceptance.Special highlight: All the screen formsand their functionalities are designedwith the GUARDUS tool set and saved inthe database as versioned and capableof validation. Due to this architecture,

all customers implement the GUARDUSApplication Engine in the standardunchanged.

Result: GUARDUS MES’ complete release-capability and a maximum of softwarequality. All production and process data areunited in a system: a holistic technologyfrom the quality and production data tomachine data and product traceability.

� Workflow Management

� Multilingualism (Unicode)

� User Management and Detailed User Right Concepts

� Document Management

� Audit Trail (Logbook)

� Release Management

� E-Mails, Links, Attachments and MS-Office Integration

� Graphical Objects for Evaluations

� Interface and Report Designer

� Browser Capability and Terminal Server Capability

� Function Trail and Validation Capability

INNOVATION



GUARDUS MES a Cockpit for Individual Performance Indicators

The GUARDUS MES catalogue forperformance indicators contains all therelevant key performance indicators (KPIs)for quality and production management.Its configuration is the result of many yearsof experience in dealing with performanceindicators, not only gained from thecustomer environment, but also from theactive participation at various national andinternational MES committees, for examplethe working committees of DIN/ISO andVDMA.

Through the GUARDUS MES homogeneousdata platform, the cockpit module serves forthe visualization of all product and processperformance indicators in an individualway– as warning systems, diagrams, tables,or through drill–down functions. Thus, eachuser is provided with the data needed forhis/her tasks – whether process indicators inthe production chain or KPIs for the monthlyor quarterly reporting for top management.In order to deliver efficient cause-and-effectanalyses, GUARDUS MES opens up various

perspectives when analysing KPIs: datafrom inspection orders, production units,production orders, information on personneland individual products – are used asindicators to create periodic or point-in-timeKPIs for every level of manufacturing.

GUARDUS MES: Innovative technology providingthe highest quality standards for the highly available shop floor.

Key Performance Indicators

� Allocation Rate

� Throughput

� Allocation Efficiency

� Utilization Efficiency

� OEE

� NEE

� Availability

� Effectiveness

� Quality Rate

� Setup Rate

� Technical Efficiency

� Production Process Rate

� Actual to Planned Scrap Rate

� First Pass Yield (FPY)

� Scrap Rate

� Rework Rate

� Defect Rate

� Fall off Rate

� Machine Capability Index

� Critical Machine Capability Index

� Process Capability Index

� Critical Process Capability Index

� Delay Rate

� Scrap Costs

� Corrective Action Index

� Scrap Cost Index

� Energy Consumption Indicators

PHILOSOPHIE

22

The support of modern MES softwaresolutions on your way to Industry 4.0In the industrial manufacturing companiesof the future, the intelligent partswill find their optimum way throughthe manufacturing process withoutany outside help. This autonomoustechnosphere is only possible ifpeople, products, machines, and toolscommunicate closely along the productionchain. Software systems, such asGUARDUS MES, will play an importantpart in the collection, visualization, andmonitoring of all the quality and productionrelevant products and process data.

Intelligent Assistance Systemsand Method SupportThe automation level of the futurescenarios of Industry 4.0 will allow for theincreased employee’s contribution withhis/her experience and decisions to theevents occurring both on the shop floorand at the management level. Being ableto make quick and well-founded decisionsin every place at any time has become anincreasing necessity.

The GUARDUS MES concept “Comfortby Design” takes into account all theserequirements, offering not only userfriendlycollection and presentations of product and process data, but also intelligent assistance systems that provide the user with the exact information that he/she needs in the process. Thus, intelligentdialogue interfaces as well as businessapp concepts, and context-sensitive function clusters will adapt themselves tothe user’s tasks related to the situation,product, or customer.

Industry 4.0

SOLUTIONS



The extremely flexible technology platformof this scalable software solution repre-sents the basis of an extensive set ofstandard functions. The perfectly tailoredcomponents allow rapid access to the ITlandscape of the shop floor. The turnkeyquality management software suite inclu-des project management (APQP), initialsampling, and the stamping of drawings.For the systematic conception and executi-on of various inspections in production, theusers will make use of GUARDUS functionsfor inspection planning.

All the tools for quality inspections ingoods incoming and production (in-pro-cess controls), as well as for final inspec-tions and acceptance reports are alsoprovided by the MES solution. Integratedfunctions for statistical process control(SPC) such as electronic defect collector

charts and extensive measurementequipment management functionalitiesaccelerate inspection processes along theentire value chain.

The ‘Complaint’ and ‘Action Management’module provides efficient management,control, and processing of inspection re-sults. A wide set of pre-configured reports(such as the 8D reports) and graphicalevaluations (control charts, distribution dia-grams, traffic-light functions etc.) instantlysupply relevant analyses and enhance thecontinuous improvement process.

The production management modulesuite, on the other hand, focuses on themanagement, dispatch and processing ofproduction orders as well as the automa-ted collection and preparation of all machi-ne and production data, including subsets

and order completion notifications. This in-formation can be quickly evaluated throughpreconfigured performance indicatorssuch as Overall Equipment Effectiveness(OEE).

Moreover, the ‘Production Management’module of GUARDUS MES also allows thecontinuous and systematic maintenanceof tools and facilities. When defects arediscovered, GUARDUS MES ensures thetraceability of every characteristic of everycomponent and raw material via batch, lot,and serial numbers. Thus, the completeproduction process can be traced backthrough every manufacturing step alongthe value chain down to the individualsuppliers. Current product and processdata are displayed automatically or at theuser’s request.

Our System for Your Solution

The implementation of the specific customer requirementsin the standard software –a unique characteristic of our software architecture.

Product- andProcess Data

PredictiveQuality

Supporting Systems

Learning Systems

Integration Connected World

Apps Internet of Things (IOT)

GUARDUS Solutions AG continues topursue a strategy of internationalizationof both its products and clientele. Thisstrategy is supported through its teamconsisting of over 50 employees workingin Ulm (Germany), Montréal (Canada), andTimisoara (Romania).

Currently, the MES application is alreadyused in enterprises in over 20 countries, onvarious network topologies such as termi-nal server and web server architectures, for

24/7 availability anywhere, anytime. In thesame way, the GUARDUS support team isalso available for all customers all over theworld.

GUARDUS MES communicates in thelanguage of each country – not only in thesystem texts and field descriptions, but alsoat the master data level. All screen formsand printouts are provided in the languagerequired by the user or function.

The result: when using GUARDUS MES,productive organizations are able tooptimally support their internationalizationstrategy at every level of their IT integrationinto the production process. Thus, qualityand production management teams fromall over the world can work together usingthe same software with their own wordsin their own language with the help ofthe GUARDUS Manufacturing ExecutionSystem.

GUARDUS Solutions AG Postgasse 1 89073 UlmDeutschland

Phone +49 731 88 01 77-0Fax +49 731 88 01 77-29E-Mail [email protected]

GUARDUS S.R.L. Aida Nr. 5 300696 Timisoara, Rumänien (RO)

CONTACT

www.guardus.de/en

GUARDUS MES worldwide

GUARDUS MES

Documents

Transcript of GUARDUS MES