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Manufacturing Execution System (MES)

Manufacturing Execution System

Shop Floor Instructions published directly from Assembly Planner's Process Engineering database complete with annotated images, videos, documents folder and even viewable 3D models are complete with effectivity based on date, series, or even serial number.  Our MES automatically generates unit specific work instructions for each operator based on each Order's Model and Options list.  Engineers can request for data collection involving serial numbers or quality parameters as well as images and video which are stored with each serialized product.  Contains detailed Time capture, Issue alerts and support for controlling and logging devices such as DC Torque Tools or Industrial Internet Of Things (IIOT).

Auto-generated Instructions for Each Order

Work instructions are automatically filtered and deployed to the shop floor so that shop floor workers do not have to sort through all work instructions for all models; only work instructions that apply to the unit are shown.  Instructions are published to the MES system with date, series or serial number effectivity, and each operator logs into a pre-defined station position to ensure that every operator gets exactly the correct set of instructions for a specific order on the date that order is produced.

Operator Sign On and Sign Off

Operators sign on and sign off of each unit they work on, generating unit genealogy, time data, unit tracking, process verification, and accountability.  Our MES system also allows operator to define when they are on break or when the station is shut down for a worker-selected reason.  Station sign-offs, breaks, and shutdowns are all logged and reported to provide quick response from supervisors and more accurate process time tracking for engineers.

Unit History Tracking and Reporting

Collect and maintain accurate records of which operators completed which steps at which stations and when, work instruction revisions used for each completed unit, missing or damaged parts during build process, serial number collection of serialized parts, critical tooling data, and more. A live process tree shows the completion status of each unit at each station.  

Serial Number and Part Validation

Through barcode scanning, verify that the correct part has been installed.  This is typically a challenge to maintain in other MES in high mix/low volume environments.


Critical to Quality Tests

Collect testing inputs and enforce role-based sign offs for critical to quality tasks.

Supporting Documentation

Images, videos, audio files, CAD drawings, and internal or external webpages can be viewed or opened from work instructions.  Common document formats, such as DOC and XLS are auto-converted to PDF so that workers can view them from any web browser.

Change Request Management

Users can easily file process or instruction change requests without having to search for a change request form or leave the shop floor.

 

Assembly Equipment Support

The MES Viewer supports a wide range of external workstation devices such as Light Boards, Torque Tools and Dimensional measuring equipment.  Some of this support is direct between our MES application and the device, or via the Azure IOT hub.  In other cases, we provide support via an interface to some of the popular MES hardware vendors such as Pivotware, and others.  Please contact a Proplanner Sales Engineer for more information on what we have done and what we can do for you!

  • Measurement equipment
  • DC Torque Tools
  • Lightboards

Andon System

Factboard is Proplanner’s ANDON Dashboard environment for the shop floor.  With Factboard, users can display the real time status of one station, all the stations in a line or department or even all of the stations in the factory, limited only by the size of their display.  Factboard is uniquely tailored to the display of assembly lines or departments where the sequential routing of part movement between those stations is pre-defined.  Units or Orders (hereafter referred to as Units) can skip stations in the sequence but movement to downstream stations is implicitly defined in Factboard which means that users are not required to BOTH sign-on and sign-off of the unit for Factboard to understand the progression through the factory. Blog Here

Factboard visualizes, logs and reports the status of transactions which can come from our Shop Floor Viewer/MES system, or from any device capable of creating a JSON text file and posting it to the web service address of the Factboard server (Hosted Locally or on Cloud).  Andon display screens are completely configurable and support an unlimited number of views which can be tailored to the needs of any user capable of accessing the system.

Wearables Support

Proplanner supports a wide range of display devices with our MES Viewer, Andon Display and PFEP Scanning interfaces.  Our partnership and integration with Proceedix, also provides support for a wide range of wearable devices such as Google Glasses.  With this integration, shop floor workers are able to sign onto an order and receive the work instruction information specifically on that product for the operator position they are logged into.  In addition, images, video and responses to questions (textual spoken or scanned) are stored back on Proplanner to enhance the record of assembly captured for each operator on each product produced.  Blog Here

Do you wish there was an easier way to update work instructions than making the same change in multiple documents and manually reformatting each one in order to maintain standards?
Proplanner utilizes rule-based template to automatically configure the work instruction document based on the defined process plan.

Are you being asked to confirm which components were installed on units, who installed, and when?
Dashboards and reports are available to track who installed components, the serial number of the components, when the component was installed, and any issues that were found.

Proplanner's Shop Floor Viewer allows for electronic work instructions to be rapidly deployed to ensure that operators are always receiving the correct information after an ECO or line rebalance goes live.

  • Responsive web page is viewable on large TV monitors, desktops, touch screens, and laptops

  • Display images, videos, tool requirements, part requirements, CAD files, PPE icons and more

  • Operator sign on/off of units with change notifications/approval and time tracking

  • Capture component serial numbers and installed revisions with validation logic

  • Capture operator comments per station and issue/track work instruction change requests back to engineering team

  • Create part or unit based roadblocks for communication to both upstream and downstream stations of defects

  • Process tree summarizes all open & closed issues along with a graphical view of pending, incomplete, and closed activities

  • Bi-directional communication with logistics team related to overall tracking of kit carts, delivery status of known skipped parts, and triggering hot call kanban process for missing parts

  • Control system access and privileges with customizable roles

  • Hundreds of configurable preferences allow for system to be customized per your business rules (ie can a unit enter Station 2 without sign off at Station 1)

  • Effectivity based on dates or unit serial numbers provides a sophisticated system for phasing in ECOs and line rebalances

Proplanner provides a single system for engineers to create a plan for manufacturing. We suggest you review these solutions next:

PLM

PFEP updated driven by BOM/Engineering Change

APP

Activity part consumption signals parts requirements at a station

APS

Kitting pick list sequence automatically updated after units are re-sequenced

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