Manufacturing Execution Systems
Projects
We have helped many customers reduce costs and increase profit, with well engineered MES projects. Our experience covers many industries and aspects of MES, such as the following examples ....
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Controlsoft has several case studies which can be obtained through an email request. Please see our contact details for further enquiries. |
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Automotive - Traceability System ensures compliance and improves efficiency
This Melbourne based auto components manufacturer needed to improve performance to remain internationally competetive, and also had to comply with strict new genealogy recording requirements for its automotive customers. Some production lines had an existing French traceability system, which was inflexible and difficult to maintain. Our new Traceability System (LineTrac) now covers the existing and new production lines, and provides the following benefits:
- secure traceability data for 15 years, with the last 2 years available online
- dramatically improved output on each production line, due to automation and reliability of the traceability task
- customer can reconfigure lines to suit new products easily
These outcomes were realised with a combination of technologies, including Microsoft SQL Server, OPC, Profibus, barcode readers and printers, and high performance networking, server, and PC equipment. LineTrac integrates with the production line HMIs and S7 PLCs, providing operators with messages and prompts to ensure that manufacturing processes are adhered to. It records production data, maintains it securely with a highly robust replication and backup regime, and provides reports on WIP, production stastistics, and management information.
Please see our contact details for further enquiries. |
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Food - Production Management System
A long term customer of our PLC and SCADA services, this international food manufacturer called upon us to implement a major MES initiative at one of its Victorian production facilities. The new system initially incorporated production management and scheduling, recipe storage, batch recording and reporting. Key aims of the project included ....
- download production schedules automatically from head office ERP system
- significantly improve process performance
- utilise existing control systems architecture
- install without disruption to production
- reports to be available for all users on the corporate WAN
- enable local review and options of production scheduling, on existing SCADAs
- interface with existing SCADA and PLC for batch initiation and data collection
- system to be easily expanded.
- complete data accuracy and robustness
All of these aims have been accomplished, saving $000s per annum. The customer now has realtime production information and analysis tools available anywhere on the corporate WAN, and has subsequently made several additions, fine tuning further areas of the plant through the intelligent use of data collection and analysis, with collaboration across various databases. For example, one of these additions enables the on-site production supervisor to review costs of raw ingredients cross-referenced against the expected usage for particular product runs, based upon line, history and recipe type. With the press of a few buttons, they can determine which combination of ingredients will result in the lowest cost per kg of product.
Please see our contact details for further enquiries. |
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Dairy - Traceability System saves $800K per annum
This high quality, specialised cheese manufacturer makes product for domestic and international markets. To satisfy overseas customer requirements (in particular Japan) or product traceability throughout the manufacturing process, Controlsoft were enlisted to replace the existing traceability system which was not performing on a number of fronts - failed barcode reads, and data loss being the main issues. Key aims of the project included ....
- use existing equipment where possible
- minimum barcode read and archive rate of 95% (closer to 100% achieved)
- utilise standard software packages
- reliable / robust
- 3 years of data to be available online
- long term data archived and secure for 15 years
- reports and analysis tools to be 100% web based
- extensive list of search options to be available in the reports
The project involved many challenges relating to the speed of data transfer between the various components: PLCs, DeviceNet, barcode scanners, Citect SCADA, SQL Server. Our solution took these issues into account, and combined with extensive initial site investigation and consultation, far exceeded the desired outcomes. An unexpected benefit of the new architecture was to enable tighter tolerances on product weights. With a secure record of exactly what weights are on every pallet of product, waste was reduced significanly resulting in the above cost saving.
Please see our contact details for further enquiries. |
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Controlsoft Pty. Ltd.
Control Systems Engineering
 Phone: +61 3 9558 0399
 Fax: +61 3 9558 1076
 enquiries@controlsoft.com.au |
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