Lean Manufacturing Execution System (MES) bridges the gap between the management team and the shop floor operations. The system provides real-time data to control manufacturing processes more effectively. Manufacturing Execution System gathers data from the sales/ordering process, provides instructions to the operators and equipment, and communicate the production status, material consumption, quality control and maintenance data back to the management team. This information allows management teams to examine business areas, identify areas for improvement and solutions to resolve any problems.

Manufacturers use our MES to control production operations across one or multiple plants. These applications by delivering Real-Time information help enforce procedures, deliver operator guidance to eliminate errors, enable operator-level decisions that account for the larger context, and automate track-and-trace and related recording tasks.

By Utilizing MES you can streamline plant operations and make activities more predictable. By providing operator support, production scheduling, tracking / tracing capabilities, and accurate real-time visibility into production processes.

Benefits

  • Accurate & Timely information about how the business is performing
  • Ability to monitor meter, unit & overall plant performance any time.
  • Automated aggregation of data into meaningful business information.
  • Energy Modeling and Optimization.
  • Improvement in Product consistency
  • Improvement in production throughput and yield.
  • Improved workflows and collaboration.
  • Reduction of errors, and therefore a reduction of paper and manual work, waste, and rework
  • Reduction or elimination of manual entry time and costs
  • Equipment availability and utilization tracking and analysis
  • Improved planning and streamlined schedules
  • Better Inventory Management
  • Product Quality Management and Statistical Process Control (SPC)

Our solution Trusted by hundreds of manufacturers in a wide range of manufacturing and production operations, MES is designed to drive operational improvements and substantially decrease total cost of ownership.

Energy is the most costly ingredient in all manufacturing today, whether electricity, gas, Water, steam or compressed air, energy has to be used sparingly - and optimally. With increases in utility costs, tax levies and environmental initiatives, businesses are under pressure to improve their utilities and energy consumption.

The energy management system, reduce your utility costs and carbon footprint, or monitor the effectiveness of an existing campaign, there is one fundamental factor - you will need accurate data to understand your utilities’ consumption, identify and target inefficiencies and monitor the effectiveness of your actions.

Lean Automation Introduces EMC2 for the better understanding of energy use and costs, calculate performance levels, calculate targets and model energy use. A range of techniques would be utilized, from simple to complex. These would be selected to suit the problems being addressed (rather than selecting an analysis technology and then finding a problem to suit).

An EMC2 provides information to appropriate personnel within an organization to help them manage energy use and costs. The exact nature of the EMC2 will depend on:

  • the particular site
  • the processes and plant involved
  • the cost of energy (in relation to other costs)
  • existing meters and instruments
  • monitoring and control systems
  • the data historian
  • data analysis and reporting systems
  • existing management systems

EMIS Functional Requirements

  • Monitor consumption and any affecting factors
  • Data aggregation from disparate data sources
  • Online energy balance
  • Sustainability KPIs , e.g. kWh/t, GJ/t or m3 water/t
  • Alerts for sudden changes in use patterns
  • Usage and cost analysis: product, media, process, etc.
  • Benchmark : periods, target performance, best practices
  • Optimal energy consumption target
Actions that generally need to be taken in order to address energy use in an EMP(Energy Management Program) may include one or more of the following
  • developing and approving an energy policy and strategy
  • training and actions to raise knowledge and awareness
  • energy audits to identify and evaluate opportunities
  • developing and implementing improvement opportunities
  • implementing performance management systems, including the EMC2

An EMC2 is the key element of performance management; it also provides essential support to the energy auditing process. EMC2 is a software solution that is tightly integrated into an organization’s systems for process monitoring and control and IT systems. Furthermore, the EMC2 will often be part of a larger system used to manage process (and business) performance more generally.

It is important to recognize that an EMC2 does not stand alone. It needs management commitment, procedures, organization, training and appropriate technical expertise.

Benefits

  • Early detection of poor performance
  • Support for decision making
  • Effective performance reporting
  • Auditing of historical operations
  • Identification and justification of energy projects
  • Evidence of success
  • Support for energy budgeting and management accounting
  • Energy data to other systems

Lean Enterprise Manufacturing Intelligence & Integration solution translates manufacturing data from the plant-floor into actionable intelligence for decision makers at the enterprise and business level.

Our Manufacturing Intelligence suite of solutions enable users to overcome business challenges, resulting in increased profitability, streamlined business efficiency and a strengthened loyalty to customers and vendors.

Our Solution addresses the needs to transform large amount of data generated from various related information systems into useful information in order to optimize the metallurgical production process. The solution is a blend of extensive knowledge of different industry, experience and state-of-the art technologies.

For large manufacturing operations with multiple plants even in different locations, Lean EMI&I solution addresses needs from planning to production, quality assurance, maintenance, asset and inventory management.

EMI&I uses existing data, along with estimated data points, to calculate a range of probable outcomes. This information allows a manufacturer to make more informed decisions. This analysis helps you find a solution when data is limited. Our solution consists of a data-intensive simulation whose objective is to analyze the behavior of a complex system, known as a scenario, by monitoring the impact of changes to a set of independent variables on a set of dependent variables.

Why EMI&I

  • Adaptability and flexibility
  • High level of Interactivity
  • Ease of use
  • Efficiency and effectiveness
  • Complete control by decision-makers.
  • Ease of development
  • Extendibility
  • Support for modeling and analysis
  • Support for data access
  • Standalone, integrated and Web-based

Features

  • Support for decision makers in semi structured and unstructured problems.
  • Support for managers at various managerial levels, ranging from top executive to line managers.
  • Support for individuals and groups. Less structured problems often requires the involvement of several individuals from different departments and organization level.
  • Support for interdependent or sequential decisions.
  • Support for intelligence, design, choice, and implementation.
  • Support for variety of decision processes and styles

Benefits

  • Improves efficiency and speed of decision making activities
  • Increases the control, competitiveness and capability of futuristic decision making of the organization
  • Facilitates interpersonal communication
  • Since it is mostly used in non-programmed decisions, it reveals new approaches and sets up new evidences for an unusual decision
  • Helps automate managerial processes