In this page, we continuously showcase brief and concise use cases from our customers, presenting customized and industry-specific solutions that we have successfully implemented with our MES products.
In the manufacturing area, a large screen displays live data from the filling department. Piece counts show the current order’s progress. Based on average values since the start of the order, a remaining runtime is dynamically calculated. This allows employees in manufacturing to know when the next bulk needs to be ready for filling.
Based on progress and remaining runtime, an alert can be triggered so that employees are actively notified even when they are not near the large screen.
The cavity count of an injection mold defines how many parts are produced in one cycle. This value is stored in the item master data. During data acquisition, cycles are counted and multiplied by the cavity count. If a cavity is deactivated, employees manually adjust the cavity value during production.
If a mold produces multiple product types simultaneously (e.g., left and right parts), quantities must be assigned to the correct orders. This can be handled by booking a negative bill of materials position or by combining two orders for joint production.
When scrap is produced, employees remove it at a later process stage without stopping the extruder. To track product quality in meters during extrusion, buzzers are placed along the line. Employees press either the “good” or “scrap” buzzer to indicate product quality. A machine signal from the feed system assigns the produced meters to the correct quality category.
To accurately track material consumption and improve inventory accuracy, additives can also be tracked automatically during extrusion. Employees assign the material to the feeders, and the machine control reports the throughput.
Employees first schedule production orders on the machines. Then they select the appropriate tool. The availability of the tools is taken into account by storing them as resources and matching inventory with demand.
Combinations are imported from the ERP system and created in the software as production variants. All options for which machines and tools can be used to manufacture an article are mapped there.
A production line consists of several interconnected machines. Between the processing steps, inspections take place, such as the checkweigher and the metal detector. To determine where each reject occurred, multiple sensors are installed. The counters are automatically calculated to assign good and reject quantities along with a differentiation of reasons.
Based on reject counters, inspection orders can be triggered during production. This enables employees to check quality and implement changes to the process immediately.
Before the shift ends, employees set up a fresh coil on the stamping and bending machine. From home, they can monitor production live via the FASTEC 4 PRO app. The MES detects machine malfunctions and displays the cause of the issue in the app. On-call employees can then decide remotely whether a trip to the facility is necessary for troubleshooting.
Employees can receive push notifications via the FASTEC 4 PRO app to be automatically alerted about production disruptions during the ghost shift.
Before production starts, employees assign orders to specific sides of the rotary table in MES FASTEC 4 PRO. When machining begins, the system receives a signal from the machine indicating which side is being processed. FASTEC 4 PRO then automatically registers the order and records order-related data.
This order-based data collection can also be applied when integrating a pallet changer. Orders are assigned to different pallets, and MES FASTEC 4 PRO registers orders automatically based on machine signals.
Using MES FASTEC 4 PRO and RFID chips embedded in the molds, the manufacturer tracks how often each mold set passes through the washing system in production. After a predefined number of cycles, the system automatically prompts operators to replace the mold set.
Washing temperature also impacts mold lifespan. By collecting process data, the manufacturer can determine how many times a mold set can be washed at a given temperature. Based on this, lifespan predictions can be made.
The bidirectional exchange between MES FASTEC 4 PRO and the machine via the OPC UA server enables the transfer of information. The system directly transmits order data, such as the target quantity, to the machine. Once this quantity is reached, the machine automatically stops and locks, preventing overproduction.
A scaled-down version of data transmission is also possible, allowing for operator guidance without direct intervention in the machine control system. In this case, target values are displayed on the HMI, and alerts notify employees accordingly.
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© FASTEC GmbH 2024
+49 5251 1647-0
© FASTEC GmbH 2024
+49 5251 1647-0
The 15-inch touch terminal is required for each machine. It has a universal RFID reader and two digital inputs for machine connection as standard.
Both the terminals and the machines are connected to the EdgeBox via LAN or WiFi. The cloud connection is made via your network or mobile communications. At least one EdgeBox is required. The system can later be moved to your own server.
Personal users are required to report the collected data. The number of employees involved in data acquisition in your production does not matter.
Each line and machine in your production is licensed individually.
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