C-MES:Production management

C-MES: Production Management is not a standalone product. It is a set of modules that extend the typical functionality of Odoo ERP or serve as an extension for 1С:ERP WE. By utilizing these modules, clients obtain all the functionalities described below. With these modules, users gain capabilities such as optimized planning, real-time process control, efficient communication, and integrated reporting, significantly enhancing the performance and productivity of their manufacturing processes.

Benefits

• Quickly and flexibly respond to unforeseen events during production, minimizing impacts on quality.
• Connects planning and production departments through coordinated end-to-end shipment-production-supply schedules based on equipment availability and technological features, tracking them with real-time updates.
• Provides tracking and high visibility of production to improve customer service (timely production and delivery of products to the client).
• Increases asset utilization efficiency and monitors business performance indicators such as KPI, OEE, highlights bottlenecks, and reduces downtime.
• Improves daily practices and employee interactions through terminals and common equipment screens.
• Promotes continuous improvement techniques for quality assessment and defect tracking with automatic classification.
• Provides a real-time visual overview of the shop floor, transmitting data to other industrial or corporate information systems, acting as the "single source of information.

Special Features

C-MES: Production Management includes a complete set of integrated modules for handling the entire workflow. Specifically designed for the metal, film, and paper industries, the system combines many years of C-MES Solutions Ltd.'s expertise in these areas, requires minimal configuration, and can be deployed in less than 12 weeks at the enterprise.

Key Features

• Automatic generation of demand based on customer orders placed for production.
• Automatic selection of the optimal route for manufacturing semi-finished and finished products from various alternatives.
• Automatic formation of production batches.
• Automatic generation of cutting plans and production tasks or loading from external applications.
• Built-in material cutting calculator (1D, 2D, 3D).
• Supports curvilinear cutting for 2D.
• Management of the status of cutting plans.
• User permission assignment for data, forms, views, and reports.
• Associated quality control profiles for targeted laboratory tests and restrictions for different groups of products and materials (by brand, thickness, specific gravity, etc.).
• End-to-end traceability of batches and their properties.
• Applying the results of parent tests to daughter products.
• Real-time consumption of materials and raw materials.
• Recording and monitoring equipment stops, including causes, to identify pain points and assist in maintenance.
• Access to data and reports on mobile devices to provide relevant information to operators outside terminal stations.
• Label printing for product identification, including barcodes and RFID.
• Storage and display of detailed production history and quality for each batch.
• Calculation of optimal packaging formats for loading cars, containers, and wagons.
• Transfer of shipping and billing information to ERP to support shipping from the finished product warehouse.
• Integration with production equipment for sending shift tasks, work instructions, and receiving real-time updates from production.
• Remote reports to measure OEE, and other required key performance indicators.
• Extended analytics for correlating quality issues with measured process parameters.
• Detailed tracking of the location of each material accounting object (sheet, roll, product, etc.).

Why Buy C-MES: Production Management?

C-MES: Production Management is designed specifically for the metallurgy, plastic films, nonwovens, and paper industries, leveraging C-MES Solutions' many years of experience with such manufacturers. The system requires minimal configuration. As a "boxed" solution, the risk of unsuccessful implementation is much lower compared to adapting other production solutions to the specifics of production, and the time required for return on investment is much shorter.

It is designed to operate 24x7. Based on PostgreSQL (Odoo ERP) or Microsoft SQL Server DBMS (1C:ERP WE), we have extensive experience integrating with most modern ERP systems, as well as process control systems using an OPC server (or direct connection with PLCs) and laboratories, quality control systems, and warehouse management.

Functionality Overview

The functionality of C-MES: Production Management includes:

• Register and manage customer orders.
• Production planning and execution.
• Traceability and genealogy of products and materials at all stages, including geometry.
• Formation of cutting plans for sheet and roll materials.
• Use of information on production waste, including planned waste.
• Create and print custom labels.
• ERP integration.
• Integration with process control equipment.
• Collection of quality information.
• Tracking of resource specifications and standards of consumption of raw materials and materials.
• Order scheduling and delivery scheduling.
• Warehouse management.
• Performance and cost analysis, reporting.

Register and Manage Customer Orders

C-MES: Production Management users can manually place customer orders, receive them from other systems, including CRM, ERP, and from internet sites.

Production Planning and Execution

C-MES: Production Management users can view the planned schedule in both graphical and tabular format. C-MES: Production Management allows controlling production activities on any equipment or station in the shop, including furnaces, continuous casting plants, extruders, paper machines, primary and secondary cutters, and more.

Traceability and Genealogy at All Stages, Including Geometry

C-MES: Production Management architecture allows tracking any production operation and easily simulating all processes in a factory. This feature helps in the event of customer claims. C-MES: Production Management tracks every semi-finished and finished product with a complete change history. An intuitive diagram shows the genealogy and information about each stage of production.

Create and Print Custom Labels

C-MES: Production Management automatically prints labels after each operation with fully customizable information and layout, including barcodes and RFID. The system fully leverages built-in label printing tools integrated within Odoo ERP and 1С:ERP WE. These built-in tools provide seamless and streamlined label creation and barcode printing, eliminating the need for additional third-party software. Users can design and print labels according to their specific requirements, ensuring that all necessary information is included and formatted correctly.

For Odoo, the system uses the robust Label and Barcode Printing modules, enabling easy customization and printing directly from the ERP interface.

For 1С:ERP WE, the integration utilizes the inherent labeling and barcode printing capabilities, allowing for efficient and accurate label generation and printing as part of the workflow.

ERP Integration

Our customers can demonstrate close integration with the following ERP systems:

• Odoo
• 1C
• SAP R / 3
• Microsoft Dynamics
• Bpsc
• JD Edwards

Integration with Process Control System

C-MES: Production Management was designed with an extensible architecture to support a wide variety of protocols and devices used in industry. Customer factories can demonstrate our large collection of interfaces, including Metso BDM, plastic extruders for automatic roll registration, Gloucester, Davis Standard, Brampton, Kiefel, wrappers, duplex cutters, scales, and wrappers through OPC servers.

Quality Data Collection

C-MES: Production Management can collect values for quality characteristics, either from sensors (in real-time) to automate process/historical data or by user input. Similarly, C-MES: Production Management records an arbitrary number of location-specific defects for the production of rolls/sheets/profiles. Identified defects and assessment of quality parameter values, depending on requirements based on customizable reaction templates for events, can trigger automatic actions, such as marking items for reworking or further testing by the quality service.

Overall Equipment Efficiency (OEE)

The OEE module allows users to request historical data to analyze equipment availability and performance, as well as product quality. By default, the OEE performance benchmark for the work center is traffic color coding in three-color mode. C-MES: Production Management records production parameters, including collecting information about process measurements, such as thickness, pressure, energy consumption, etc. It also includes a data analysis tool that captures and stores such information. As a result, this tool allows you to:

• Diagnose/troubleshoot.
• Generate reports.
• Identify opportunities for improvement.
• Track downtime.
• Keep track of costs and energy consumption.

Transportation and Shipment Planning

C-MES: Production Management plans transportation orders based on specified routes. Functionality includes:

• Different loading, shipping, and delivery calendars can be assigned to each route.
• Users can verify that the settlement plan is correct and allow C-MES: Production Management to do planning according to established rules.
• Alerts when orders are late compared to the planned shipment date.
• Creating a document for the transportation of each order.
• Automatic calculation of optimal order packing.

Warehouse Management

All material is addressed and monitored, allowing operators (e.g., truck drivers) to know which material to pick up and where to place it, regardless of its location, e.g., before a conversion operation, in a warehouse, or on a vehicle leaving the plant. C-MES: Production Management maintains a hierarchy of production sites, warehouses, and storage cells. C-MES: Production Management can interact with third-party WMS systems. C-MES: Production Management supports packaging (grouping of items), for example, a pallet on which different items are placed. The container can be moved as a whole, rather than as separate items.

Performance and Cost Analysis and Reporting

All equipment events are recorded (input, output, stops, breaks, starts, etc.). Reason codes and comments can be entered by the operator/shift manager before the shift ends. Production and efficiency reports by machine, shift, product, raw materials, etc., are generated and compared with "ideal" production scenarios.

In Odoo ERP, the reporting is facilitated by the built-in Odoo Studio and Reporting modules, which allow users to create comprehensive and customizable reports directly within the ERP interface. These tools provide a flexible and user-friendly way to design, generate, and modify reports according to business requirements.

In 1С:ERP WE, the system utilizes the built-in DCS (Data Composition System), which is a powerful tool for creating highly customizable and detailed reports. Users can design and generate reports tailored to their specific needs without requiring external software.

These built-in reporting tools ensure that C-MES: Production Management users can easily create, customize, and generate reports to meet their specific needs, streamlining the performance and cost analysis process.

Shift Control

Shift assignment management includes:

• Generate shift tasks for a given calendar interval.
• Register actual production operations, used equipment, labor operations, and materials manually and using shop floor terminals, as well as receive this data directly from the equipment.
• Allows customization of response patterns for events and commands consisting of a supervisor and operators.
• Statistics are maintained, determined by the qualifications and skills of the operator, and the technological features of the equipment unit, allowing calculation of the production schedule and assigning shift machine tasks based on these statistics.
• Allows operators to enter notes when registering the fact of production and transmit instructions for the next shift. They are easily accessible from production screens. You can search, read, and print shift reports.
• This functionality allows operators to register activity records electronically to increase production management efficiency and speed up the decision-making process.

C-MES: Production Management created the first advanced planning system designed to solve your planning problems and allow you to focus more on your business goals. C-MES: Production Management provides short and medium-term planning opportunities for your business. The system allows simulating complex multi-stage production processes, organizing tasks at each work center, and estimating start and end dates with several limitations.

C-MES: Production Management is easily customized for your industry, particularly if you work in industries producing or processing rolled or sheet products, such as plastic films and flexible packaging, nonwovens, metals, paper, and cardboard products, as well as mechanical manufacturing.

Benefits of Using C-MES: Production Management

• Improved customer service by enhancing quality and reducing production time.
• Inventory reduced by at least 30%.
• Order fulfillment failures reduced by at least 50%.
• Order status is monitored through an integrated system.
• Increased overall performance by reducing downtime and equipment setups.
• Production cost control reduced by at least 25%.
• Work in progress reduced by at least 20%.
• Waste costs (depending on production) can be reduced tenfold.
• Stock shortages reduced tenfold.
• Changeover costs reduced by at least 15%.
• Overall productivity increase of the planning department by 400%.

Additional Benefits

• Increased production transparency.
• Improved traceability and product quality.
• Quick return on investment.

Note: Since the functionality of Odoo ERP and 1С:ERP WE systems differs significantly, the functionality of the extension modules for Odoo and 1С:ERP WE may also vary, leading to differences in the final system functions. Therefore, it is recommended to consult with our technical specialists before making a purchase decision.