Manufacturing Execution System
While many great MES systems are available, few are tailored specifically to the task of complex assembly. Fundamentally, the assembly line is a series of highly variable, worker-dependent operations as opposed to the more consistent, repetitive, machine-dependent operations often addressed by traditional MES applications.
Proplanner's assembly oriented MES (Shop Floor Viewer MES) and Andon (Factboard) systems make extensive use of the highly detailed and model-option coded (variant) Assembly Planner process database in providing a bi-directional flow of task-level information between manufacturing engineers and shop floor workers.
Shop Floor Instructions published directly from Assembly Planner's Process Engineering database with annotated images, videos, controlled documents and even interactive 3D models are released via 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.
PowerBI Reporting on MES and Factboard
Proplanner’s new Power BI connector for Shop Floor MES (SFV) and Factboard allow you to combine, summarize and report on the vast amount of data collected by those systems. This data can then be aggregated, filtered, analyzed, formatted, charted and displayed per your needs and even shared among other users in your company.
Shop Floor MES collects data about every Activity performed by every user on every unit. Additionally, engineers can choose to ask the user to scan or enter additional data as they perform Worksteps inside those activities. Since all Industrial Internet of Things (IIOT) interfaces, such as DC Torque Tools, Pick-2-Light Systems, or PLC’s are connected to SFV Worksteps, this means that all collected data from those systems is available as well.
Factboard receives Posted transactions from SFV and any other factory systems capable of sending a JSON Posted messages. Often these transactions involve key shop floor events such as products arriving and departing stations, Assembly line stoppages, or Quality and Logistics issues. These transactions, including all of their attribute data are available to Proplanner’s PowerBI connector.
To take advantage of this powerful new capability, find the Proplanner connector, (included free to all subscribers) and connect to your dataset, then sign into your Proplanner account and then the connection will be established. When you open your Power BI session this connection will provide access to all the SFV MES and Factboard data tables. Check out our blog here
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 operators 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 a 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 the 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
Shop Floor Picture and Video Collaboration
Proplanner’s new Shop Floor Viewer now allows workers on the floor to capture Pictures and Video from their phones, tablets and USB Cameras and associate those images to Activities/Worksteps in the Process as well as to the specific unit (order) they are working on. Using the new MES CAD Viewer feature, workers can also store snapshots from CAD models which are contextually available to them.Additionally, any file type (PDF, XLSX, DOCX, etc.) can be saved and associated both to the Activity/Workstep and the specific active unit they are working on.Workers can also annotate Images, Videos and Documents to enhance collaboration and communication among themselves and the engineering team.
With this powerful new capability, Engineers and Workers can visually and textually collaborate in real time which substantially enhances the quality of the shop floor documentation while reducing the time and effort to both create and maintain.
Since all of this collaboration is linked to both the Process and the active unit (order) being processed the worker is simultaneously recording unit-specific issues while effectively communicating to their peers and engineering team the active issues of the day.Phone calls, texting and email traffic is reduced, and searchable issues management and documentation is enhanced, in a way that is easier to the worker than any other option available to them. Check out our blog here.
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.
See a Workstation Demo Video here!
Watch a short video on our secure multi-tier Architecture and Optimal Workflow here!
Bar Code Scanners
PLC's and Measurement equipment
DC Torque Tools (Atlas Copco, Cleco, Desoutter, etc.)
Andon Light Towers
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 the 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 that can be tailored to the needs of any user capable of accessing the system.
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, videos, 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
Interactive 3D Model View and Markup
Shop Floor Viewer's latest enhancement allows operators to view the 3D CAD model directly within the work instructions as they navigate the assembly process. Operators can also manipulate the 3D model, apply their own markups, and create custom views. This brings an end-to-end connection between the engineers designing the assembly process within Assembly Planner Virtual Build module and the shop floor operators utilizing the work instructions, all sharing the same 3D Model. 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 a 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.
A 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 request back to the engineering team.
Create part or unit-based roadblocks for communication to both upstream and downstream stations of defects.
The process tree summarizes all open & closed issues along with a graphical view of pending, incomplete, and closing 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 the 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:
PFEP updated driven by BOM/Engineering Change
Activity part consumption signals parts requirements at a station
Kitting pick list sequence automatically updated after units are re-sequenced