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Table of Contents

1. INTRODUCTION .................................................................................................................................... 4

2. WHAT IS PLANT MANAGER? ................................................................................................................. 5

3. FEATURES OF PLANT MANAGER............................................................................................................ 5

4. INSTALLING PLANT MANAGER .............................................................................................................. 5

5. COMPARATIVE ANALYSIS OF COMMONLY USED METHODS FOR RECORDING PLANNING AND

SCHEDULING DATA WITH PLANT MANAGER ............................................................................................. 6

6. BENEFITS OF PLANT MANAGER ............................................................................................................. 8

7. PLANT MANAGER SOFTWARE ............................................................................................................... 9

7.1 Dashboard ......................................................................................................................................... 9

7.2 Machine Masters .............................................................................................................................. 10

7.3 Select Machines ............................................................................................................................... 11

7.4 Daily Production Input ...................................................................................................................... 12

8. PLANT MANAGER MOBILE APPLICATION ............................................................................................. 13

8.1 Dashboard ....................................................................................................................................... 13

8.2 Job Card Status report ...................................................................................................................... 14

8.3 Order Status Graph........................................................................................................................... 14

8.4 Order Status Report ......................................................................................................................... 15

8.5 TV Display on the Shop Floor ............................................................................................................ 16

INDEX .................................................................................................................................................... 17

TABLE OF FIGURES ................................................................................................................................... 3

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Table of Figures

Figure 1 Plant Manager Dashboard ..................................................................................................................... 9

Figure 2 Resource (machine) details ................................................................................................................. 10

Figure 3 Select Machines ................................................................................................................................... 11

Figure 4 Daily Production Input ......................................................................................................................... 12

Figure 5 Dashboard ........................................................................................................................................... 13

Figure 6 Job Card Status Report ........................................................................................................................ 14

Figure 7 Order status graph ............................................................................................................................... 14

Figure 8 Order Status Report ............................................................................................................................. 15

Figure 9 Internet activated device ..................................................................................................................... 16

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1. Introduction This document is a short introduction to the software Plant Manager. It contains the following

information:

What is Plant Manager?

Features of Plant Manager

Comparative analysis of commonly used methods for recording planning and scheduling

data with Plant Manager

Benefits of Plant Manager

Software specifications

Images of the software screens

Details of Plant Manager Android app

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2. What is Plant Manager? Keeping in mind the problems faced by the manufacturing industry, especially on the shop floor

and to have more control over production, planning and scheduling, CNCTimes.com has developed

a software called Plant Manager.

Offers finite capacity planning and scheduling capability

Provides greater visibility & control over manufacturing processes on a day to day basis

Minimizes throughput time

Helps to manage resources optimally

A cloud based software

3. Features of Plant Manager Multiple operation capability of a workstation can be defined into the system

Daily production capacities for different operations or combination of operations can be defined for a workstation

Multiple resources for single operation can be defined

Sequence of operations for a raw material to convert it into a finished product can be defined

Vendors, their resources, and respective production capacities can be defined

Human resource can be defined as individual work station

4. Installing Plant Manager Plant Manager is offered as Software as a service (SaaS). SaaS is a software licensing and

delivery model in which software is licensed on a subscription basis and is centrally hosted.

Plant Manager is hosted at Amazon Cloud. It needs IIS server and a SQL server for Database.

Plant Manager allows every customer to have their own Database so that read/write access

is private and secure.

Plant Manager is developed using ASP.Net technology

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5. Comparative analysis of commonly used methods for recording planning and scheduling data with Plant Manager There are various methods of maintaining planning and scheduling data. The most commonly used

are mentioned in the following table along with their characteristics.

Parameters Log Book MS Excel document ERP/SAP Plant Manager Data input

method Handwritten

Manual input Manual Manual/MS Excel

import

Safety of data Possibility of losing data

Possibility of losing data Data is relatively safe

Data is safe on the cloud

Data backup No backup

Can be backed up on the local computer

Backup on local

computer

Data can be backed up on local

computer (on demand)/cloud

Reports No instant reports.

No instant report. Need manual calculations

to get results

Instant reports Instant reports

Pricing Inexpensive Inexpensive Very Expensive

Affordable/ monthly subscription

Data interrelation No interrelation of data

No interrelation of data Data is interrelated

Data is interrelated

Maintenance of data

Tedious process Tedious process Relatively simpler

Simple

Training needs Does not require trained

manpower

Does not require trained manpower

Requires trained

manpower to operate

Requires trained manpower to

operate

Data interpretation

Drawing inference from

the data is difficult

Drawing inference from the data is difficult

Focused on other business

areas rather than planning

and micro scheduling

Reports and conclusions are easily generated

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Parameters Log Book MS Excel document

ERP/SAP Plant Manager

Calculations Need manual calculations to

get results

Need manual

calculations to get results

Difficult to get accurate shop

floor data

Easy to get accurate shop floor data

Usage Was used extensively before computers became common

Is used extensively but is not tailored for storing shop floor data

Not used commonly for storing shop floor data

Only designed for storing shop floor data

Implementation Not Applicable Not Applicable

Implementation takes a lot of time

Implementation is easy and quick

Table 1 Comparative analysis of different methods of recording planning and production data

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6. Benefits of Plant Manager

Improve productivity on the shop floor

Get correct data from your shop floor

Reduce churn in production plans

Greater visibility & control over manufacturing processes

Improve resource (Machine/Personnel) utilization

Optimally utilize all your machines

Get shift wise plans for each operator

Get real time information on all activities

Save Time and Money

Plan / Re-plan efficiently within seconds

Productivity improvement – deliver on time

Save costs on the shop floor

Grow Your Business

Optimally utilized machines and operators

Maximize production accuracy

Improved planning, budgeting, and productivity

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7. Plant Manager Software

7.1 Dashboard

The Plant Manager dashboard gives an overview of the status of current orders. The order status

report shows the orders that are in time and orders that have become overdue.

The graph provides a visual representation of the percentage of completed orders with respect to

job card number.

Figure 1 Plant Manager Dashboard

Total orders

Completed orders

Pending orders

Planned orders

In-process orders

Scheduled orders

Total number of

machines

Total number of

products

KEY FEATURES

Order

Status

Report

Percentage of completed orders with respect to job card number.

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7.2 Machine Masters

The Machine Master section includes details about

Machine Capability – Describes the machine process

Machine Details – Provides information on

1. Machine capacity – which can be assigned manually or using capacity calculator

2. Days/shifts of working

3. Machine description - Whether it is a normal or lot machine

4. Allows you to assign capabilities to machine

Machine Maintenance – Provides information on machine maintenance interval

Figure 2 Resource (machine) details

Machine

Capability

Machine Details

1) Machine

Capacity

2) Shifts

3) Machine

description

4) Assign machine

capabilities

Machine

Maintenance

KEY FEATURES

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7.3 Select Machines

You can assign machines in the Select Machines screen, after the details, and the order of the

product to be manufactured have been added.

You can also do the following procedures using the Select Machines screen.

Select multiple machines for a single process

Add setup time for a machine

Assign process dependency for all processes

Figure 3 Select Machines

Assign Machines

Multiple machines

for a single

process

Assign machine

setup time

Assign process

dependency

KEY FEATURES

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7.4 Daily Production Input

You can add real time data of the shop floor through Daily Production Input screen.

You can add the following information using the Daily Production Input screen.

Production quantity

Inspection quantity

Machine downtime

Figure 4 Daily Production Input

Add real-time shop

floor data

Add

1) production

quantity

2) Inspection

quantity

3) Machine

downtime

KEY FEATURES

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8. Plant Manager Mobile Application

Plant Manager has an Android app that allows you to see the following data

1. Quick view summary reports 2. Production data entry

The Plant Manager Android app is an anytime, anywhere “eye” on your shop floor which can be viewed through reports on your android device.

8.1 Dashboard Gives an overview of the status of orders and the summary of all orders and different processes.

Figure 5 Dashboard

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8.2 Job Card Status report

The Job Card Status Report provides information of on-time/delayed orders, its delivery date and expected completion date.

Figure 6 Job Card Status Report

8.3 Order Status Graph

This screen displays the percentage of completed orders with respect to job card

Figure 7 Order status graph

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8.4 Order Status Report

This screen displays the percentage of completed order quantity and the current status.

Figure 8 Order Status Report

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8.5 TV Display on the Shop Floor

You can broadcast the real-time production status on big screen TV’s across the shop floor by using the below internet activated device that can be attached with a VGA cable to TV screens. You can display the following

1. Daily schedule on TV on shop floor 2. Order status on TV on shop floor

Figure 9 Internet activated device

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INDEX

A

Amazon Cloud, 4

ASP.Net technology, 4

C

cloud based software, 4

D

Daily Production Input, 11

F

finite capacity, 4

G

Greater visibility, 7

I

Instant reports, 5

internet activated device, 15

J

Job Card Status Report, 13

M

Machine Capability, 9

Machine Details, 9

Machine Maintenance, 9

O

Order Status Report, 14

P

Plan / Re-plan, 7

Plant Manager Mobile Application, 12

process dependency, 10

R

real-time production status, 15

S

SaaS, 4

T

TV Display on the Shop Floor, 15

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