Making Rubber and Plastics Manufacturers more responsive with Epicor Mattec MES
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Transcript of Making Rubber and Plastics Manufacturers more responsive with Epicor Mattec MES
© 2015 Epicor Software Corporation
Making Rubber and Plastics Manufacturers more responsive with Epicor Mattec MES
© 2015 Epicor Software Corporation
● Why MES?● Epicor® Mattec® MES™:
what it is, what it does● How it works● Success stories
Contents
© 2015 Epicor Software Corporation
Why MES?
© 2015 Epicor Software Corporation
● Plastics and rubber● Fabricated metals,
metal parts● Automotive parts,
components● Electronics● Medical moulding,
instruments● Printing
What industries and verticals is Mattec MES softwaredesigned for?
● High-speed print● Extrusion● Blow-moulding● Die-casting● Metal extrusion● Cable manufacturing● CNC machining
(Computer Numerical Control)
● Assembly● Containers● Food● Pharma
● Injection moulding
● Thermo-forming
● Automated assembly
● Metal-forming
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Quality, responsiveness and capacity are key objectives
Source: “Weaving The Digital Thread 2014,” LNS Research
Top operational objectives
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● Manual/paper based time-sheets?● Epicor ERP – MES system
functionality?● Scanning bar-codes?● Direct from machines?
How Do You Collect Shop Floor Data?
© 2015 Epicor Software Corporation
Why are our machines not
running consistently
well?
What can we do to boost
quality and on-time orders?
Why are some shifts better than
the others?
We’re a “Lean” shop … why
aren’t we getting better?
OEE got better … but nothing else
did.
We can’t take on more
business unless we buy more
machines.
…but the ERP system says we can do all these orders today…
Production problems cause
schedule conflicts.
Why are we always shipping
orders “last minute”?
Are you asking these questions?
© 2015 Epicor Software Corporation
Consequences of a disconnected shop floor
Disconnected data sourcesPoor operational visibility
Disconnected job scheduling Delayed information from equipment
Yourobjectives
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Further (cost) consequences of a disconnected shop floor
Late shipments
Higher shipping costs
Unhappy customers
Penalties, fines etc
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The business case for MES software
Source: “Metrics that Matter,” LNS Research and MESA Study 2014
Average annual improvements in:
© 2015 Epicor Software Corporation
Epicor Mattec MES: What it is, what it does
© 2015 Epicor Software Corporation
An Automated Manufacturing Execution System
Mattec MES software manages:● Production monitoring● Process monitoring● Automatic part qualification● Dynamic plant floor
scheduling● Energy monitoring● Visibility, reporting and
analytics: plant and enterprise● SPC & SQC
So you can:
access accurate data in
real time
start asking the right questions
make well-informed
timely decisions
© 2015 Epicor Software Corporation
● Gather data directly from equipment via M2M and computer interfaces
● Monitor machines automatically to analyse production and performance 24x7
● Operators can easily add data to provide additional insight
Same Machines, Increased Production
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Mattec MES software helps you...
● Increase capacity without adding assets
● Improve throughput and reduce downtime
● Improve quality/reduce scrap● Improve overall OEE
© 2015 Epicor Software Corporation
How it works
© 2015 Epicor Software Corporation
The old way…
Performance and loss analysis printed
for review
Production plan generated by ERP system
Product count, scrap count, scrap reasons, downtime calculation and downtime reasons gathered manually
Data entered into ERP system manually
ERP System
Scrap
Scrap
Schedule adjustments delivered manually
Schedule adjustments delivered manually
Production
Product count, scrap count, scrap reasons, downtime calculation and downtime reasons gathered manually
Performance and loss analysis printed
for review
Production
© 2015 Epicor Software Corporation
A new approach that complements your ERP system...
Information viewed and inputted in real time
ERP System
Production plan
Schedule and production updates
• Production plan• Schedule changes• Product count• Scrap count• Scrap reasons, Downtime• Downtime reasons
Real-time exchange of information
Real-time exchange of information
Mattec MESSystem
© 2015 Epicor Software Corporation
How real-time integration with ERP software works
Scheduled Epicor ERP Import Process
Input Directory for Mattec MES Export Data
Scheduled Mattec Automatic Data Export
Process
ERP Export to Mattec Batch Process – can be manual or
automatic process
Output Directory for ERP Export Batch Data
Scheduled Mattec Automatic Data Import
Process
Epicor ERP/Mattec MES System Integration Data Flow
Data that is Exported from the Mattec MES system• Labour Details• Labour Completed Parts and the quantity completed• Labour Equipment counter associated with reported
quantities• Scheduling parameters, including company and job data,
operation data and production start and end dates
Data that is Exported from the Epicor ERP system• Scrap Codes• Indirect Downtime Labour Codes (Downtime Codes)• Resources marked as Tools (Tool IDs)• Manufactured Parts (Manufactured Items)• Production Methods and Operations (Process Sheets)• Production Jobs• Preventative Maintenance Jobs• Material Parts (Materials)• Manufacturing Employees (Operator IDs)
© 2015 Epicor Software Corporation
Providing value across the business
Mattec MESSystem
Plant analytics
Plant management
Enterprise analytics
Top floor (corporate)
Performance analyticsReal-time production displays
Spc & sqcVisual, dynamic scheduling
Energy monitoring
Plant operations
AIUShop floor touchscreen hmi
Plc, opc, opc connectorReal-time production displays
Real-time metrics
Shop floor
© 2015 Epicor Software Corporation
Success stories
© 2015 Epicor Software Corporation
Success Story
HERR GmbH optimises product at new site with Mattec MES software to safeguard growth
“Thanks to the Epicor Mattec MES software a quick overview of our real production is possible at any time. The optimisation potential is enormous.”
Cornel Herr, General ManagerHERR GmbH
Business Benefits
30% production increase
Improved quality and timelines
The Mattec MES solution is the core application for the entire production process
© 2015 Epicor Software Corporation
Success Story
Epicor Mattec MES software drives continuous improvement at Johnson Controls
“We used to run 3-4% scrap. Last month we were down to 1.37%. You can’t get much better than that; that’s world-class and is largely attributable to the Epicor Mattec solution.”
Dave Rose, Quality EngineerJohnson Controls
Business Benefits
Decreased scrap to 1.37%
Decreased machine downtime by 3.1%
13% improvement unit manufacture cost
8% increase in overall productivity
50% reduction in job changeover time
Annual cost of quality reduced by $600,000
© 2015 Epicor Software Corporation
Plano Molding uses Epicor Mattec MES software to tackle plant efficiency
“The shop floor insights that Mattec software provides helps our team drive bottom-line growth. Real-time planning and scheduling insights with Mattec software allows us to respond to our customers faster.”
Tom Dimick, Director of ManufacturingPlano Molding
Business Benefits
Drove bottom-line growth with real-time shop floor insights
Success Story
Achieved $700,000 savings in scrap improvements
Enabled real-time visibility into OEE, scrap, and cycle times
Inspired continuous improvement initiatives and teams
Improved customer experience as a result of better planning
© 2015 Epicor Software Corporation
To summarise…
With Epicor Mattec® MES™ software
Increase product, from your existing machines, using
real-time, accurate data... …helping you ask the
right questions and make well-informed and timely decisions
© 2015 Epicor Software Corporation
Thank you
Interested in learning more?Visit: www.epicor.com/uk/mes