Efficiency in industrial production is the result of a complex interaction between various elements, including human, organisational and structural aspects, including plant and machinery. The guarantee of product quality, on-time delivery and consequent customer satisfaction are strongly influenced by the level of control that can be applied throughout the entire production flow from machining and component selection to the packaging of the article ready to be shipped.
To fully document and control our production process, IDRAL has adopted new innovative solutions through the implementation of a Manufacturing ExecutionSystem (MES ). This dynamic software enables the management and control of production orders, and is designed to best suit the needs of each department. Following Industry 4.0 directives, the MES is connected to the company's management system, receives production orders from the latter and manages their execution via direct connections (automatic machining or assembly machines) and a WEB interface on PCs and tablets distributed to the different operators.
Connected automatic machines
Connected automatic machines, including collaborative robots and mechanical machining devices, interact with the company network, exchanging real-time data on their status (working, waiting, etc.) and other information, including the number of parts produced, the work programme being executed and any alarms. Processing times are automatically recorded throughout the day and the web interface allows the status of the machines and their productivity to be checked remotely.
A section of the MES is dedicated to machine maintenance: it is possible to set up an agenda for routine and extraordinary checks, in order to keep track of the activities that are essential for ensuring the productivity of the department and minimising machine downtime.
The role of operators
Manual activity represents the most significant part in the organisation of production activities at Idral; the accuracy of the records and the shrewdness of the personnel are fundamental to ensure consistent and useful data for order scheduling and statistical analyses.
Once the orders have been assigned to the work centres (e.g. the assembly table), the operators record the partial processing times of each order and the pieces produced on a tablet; from the same web interface they can also access assembly drawings, test parameters and any specific instructions for the article in production. By means of a dedicated button they can notify a production criticality (e.g. an incorrect or insufficient quantity component) or a quality criticality (e.g. aesthetic defects of the entire batch). The operators in the machining department manually record on a tablet the periodic dimensional checks carried out on the articles in production and any non-conformities detected.
Data Collection
All the data collected by the tablets can be analysed by the software in order to obtain the most realisticstatistics possible on the various machining centres and to evaluate production times for the purposes of scheduling and assessing production costs. Whenever a criticality is detected in production, an information e-mail is automatically sent to the department manager and the order is blocked in the MES pending authorisation for registration. Only the department manager, once the extent of the problem has been verified, can authorise the release of the order and its registration in the company management system.
Downtime statistics can be easily exported from the MES software: on this basis, any corrective actions are evaluated to prevent or minimise the likelihood of the same problems recurring in the future.
Benefits of the MES system for customers
Accurate management of production resources and their effective integration are key aspects for IDRAL, representing our ongoing commitment to the future. Our dedication to technological innovation and continuous research enables us to offer ever more efficient and reliable solutions. We firmly believe that only through a constant process of improvement can we guarantee quality products and satisfaction for our customers. We are here for you! For further information or personalised support, please do not hesitate to contact us. Our team is ready to assist you and provide all the answers you need.
by Alessandro Creola Production manager