ImProdis – production management
From efficient data collection to decision verification.
ImProdis is an informational indicator, analytical and reporting system, as well as a set of training and workshops supporting in the preparation and implementation of changes in the organization, consisting of the implementation and digitization (or optimization of the existing) indicator system.
1.Process control
The layer in which specific orders and tasks are carried out. It is responsible for the implementation of plans and is the source of all information and product quality.
The ImOperator and ImDiagnostics tools allow to enter real information directly into the system from the process: obtained from machines and those declared by operatos. At the same time, they provide information about current tasks to be performed.
2.Process Supervisory Control
The layer in which direct control over the current course of the process and the implementation of the current production plan is exercise. At this level, the efficiency of both entire production lines and individual work centers is monitores.
ImSupervisor and ImViewer tools support department managers, maintenance amanagers, master, brigadiers etc. They provide them with information necessary to analyse current problems as well as the possibility of operational management.
3.Manufacturing Operations
Layer responsible for supervising, monitoring production and managing operations. At this level, the level of implementation of existing plans is accounted for and new goals are set for the future.
ImPortal tool, thanks to predefined reports and carefully selected indicators, supports the management team in the process od analysing the company’s result and making decisions shaping the future of the organization.
Main Capabilities
Complete set of functions to efficiently manageand document operational processes and material flow in industrial manufacturing plants
Continuous and Direct Monitoring of the Most Important KPIs
The system continuously collects and analyzes data from machines and production processes, providing users with direct access to current information, such as production performance. Key metrics like performance, quality, machine availability, and other enterprise-specific parameters are monitored.
Recording Production Automatically, Manually, or in a Hybrid Way
Machine and equipment data can be collected automatically in real time, without the need for employee intervention. In cases where PLC information is limited, operators can manually enter additional data (such as reasons for downtime) to supplement the automatically recorded timestamps. Fully manual data recording is also supported.
Editable and Customizable Interface
The system enables users to tailor the interface design and layout to their preferences, enhancing convenience and efficiency. Users can create and modify the so-called tiles, adding or removing widgets and indicators that are most important to them.
Full Record of Production Events
All production events, including the start and completion of operations, downtimes, machine failures, and more, are recorded. The system logs data in real time, ensuring precise and up-to-date insight into the production process. It also allows reviewing event history, supporting root cause analysis and trend identification.
Application to Preview Status and Execution
The application lets users monitor production status and task execution from anywhere, also with mobile devices like smartphones and tablets. It provides current data on machine status, production order progress, and KPIs. The user-friendly, intuitive interface ensures quick access to essential information.
Centralized Resource Management
Continuous monitoring of resource status and availability facilitates quick response to changes and minimization of downtime and waste. Centralized management of all production resources simplifies resource allocation to production orders, supports decision-making, and helps identify efficiency gaps.
Production Order Management
The system simplifies the creation and assignment of production orders to appropriate resources. It ensures continuous monitoring of production order status, allowing real-time progress tracking. Prioritizing production orders facilitates flexible response to changing demands and business priorities.
Scalable Architecture
The system can be easily expanded as the production needs grow, without significant infrastructure modifications. It supports both local installations and cloud-based deployments, ensuring flexible IT infrastructure management according to company preferences.
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Starter set with monitoring for 5 machines
from 21,000 PLN annually
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from 21,000 PLN annually
Delivery process
See how we combine agile and waterfall approaches to achieve significant flexibility while guaranteeing high quality, on-time and on-budget.
1.
Project preparation
2.
Preparation
Preparation
of the implementation
concept
3.
Preparation
Preparation
of the production
environment
4.
Implementation
5.
Strabilization
Strabilization
Phase
6.
Guatantee
Guatantee
Period
We start the project with a deep and comprehensive analysis, during which a great deal of attention is paid to talking to the operators in the gemba. We conduct workshops and meetings at all levels of the organisation gathering information about problems, needs, challenges and goals. For very large projects, the analysis phase can be split off into a separate project. The analysis carried out in this way serves as our upstream kanban and creates the backlog for the next stages.
We divide each implementation phase into smaller sprints, during which selected elements from the backlog are implemented, but we also confront the scope on an ongoing basis with the client, modelling the value to be delivered at the end of the sprint. In the next step, a demo or mock-up is created to show the conceptually designed element.In the final stage, the actual development is carried out and feedback from the User is collected upon completion. Once accepted, the solution is put into production or added to the already created part of the project.
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Management by facts
The decision-making process in a production organization should be standardized so that the right and necessary information is always “at hand”, and the effectiveness and efficiency of key decisions is increased.
Management by facts is the mechanism for moving from data to information to operational knowledge and, consequently, to more effective management through more effective decisions.
Management by facts allows to gradually move away from the model of intuitive action to the model of studying the nature of the phenomenon and problem, correctly describing it and inferring (making decisions) based on knowledge.
Consult Experts
See how we combine agile and waterfall methodologies to achieve significant flexibility, while ensuring high quality, timeliness, and budget compliance.
Paweł Firek
“Effective digitalization with ImProdis
ImProdis software by ImFactory is a practice-based performance system developed from many years of experience in configuring, implementing, and creating open, dedicated systems to support industry. Based on ISA-95 standards, the solution is expandable with new functionalities. Our main objective is to ensure that every user has access to all the essential information they need, tailored to specific times and contexts. This provides the foundation and knowledge necessary for proper and effective operations at all levels of the enterprise.”
What do we deliver to our clients? How are we operating?
- We diagnose / verify the needs of the organization
- We select appropriate organizational and technical solutions, model changes and evaluate the profitability of an investment in a solution
- We prepare people in the organization for change (consultations, workshops, training)
- We implement technical solutions
- We support the maintenance and development of organizational and technical changes
Related articles
FAQ
See what customers interested in the ImProdis system most frequently
ask about and expand your knowledge on this topic.
ask about and expand your knowledge on this topic.
1.
What is an ImProdis?
ImProdis is an informational indicator, analytical and reporting system, as well as a set of training and workshops supporting in the preparation and implementation of changes in the organization, consisting of the implementation and digitization (or optimization of the existing) indicator system.
2.
What are the benefits of using the ImProdis?
Using the ImProdis positively affects OEE and productivity. It helps improve product quality and ensure better equipment availability. Implementing the ImProdis can also contribute to reducing production costs.
3.
How does the ImProdis integrate with other systems? How does it cooperate with ERP, APS, CMMS, WMS, and others?
The ImProdis offers a variety of integration possibilities. The most commonly recommended option is the use of an Enterprise Service Bus (ESB), which organizes and secures the continuity of communication in key channels, such as retrieving orders from the ERP and posting production or fetching the schedule from the APS and reporting back on plan execution progress. Other integration examples include setting up tasks in the CMMS for maintenance departments after a workstation failure is detected, or reporting component demands in the WMS.
4.
How to prepare for ImProdis implementation?
Just like any other project, the ImProdis implementation project begins by defining the problems, needs, or challenges the system should address and to what extent. Only after establishing these matters can we begin the work with identifying key users, project stakeholders, taking inventory of existing machinery and systems, and specifying the requirements. At this stage, involving an external consultant can be beneficial.
5.
Where to start implementing the MES?
Starting the implementation of the ImProdis is best initiated by preparing a demonstration version, such as a Proof of Concept or Proof of Value. This involves implementing a version of the system limited in functionality or scope, showcasing that it will be capable of fulfilling the project's main objectives. This phase serves as the business justification for the investment and results in the delivery of the Minimal Value Proposition (MVP).
6.
How much does the ImProdis cost?
The cost of the ImProdis varies based on many factors and can range from thousands to tens of thousands PLN. Key factors determining the ImProdis cost include the number of connected machines and automatic signals, user count, functional scope, licensing approach (perpetual or subscription), and hosting method (local, cloud, hybrid).
7.
Which industries typically use the ImProdis?
ImProdis is used in all industries related to manufacturing, but it excells in discrete manufacturing.
8.
What does post-implementation support look like?
Post-implementation support is divided into warranty and post-warranty (maintenance) phases. Irrespective of the period, post-implementation support involves handling Service Requests (SR), which include preparing patches and workarounds for reported errors, software version updates, system performance monitoring, and other issues to ensure continuous operation according to SLA provisions.
Another stream of requests is Functional Requests (FR), aimed at introducing improvements, optimizations, configuration changes, adding new features or areas - in essence, expanding the system. Additionally, during Gemba walks in the facility, consultants assess system usage and gather feedback directly from users.
9.
What are the development possibilities for the ImProdis?
Common areas of ImProdis development include:
• adding new functions not yet implemented,
• expanding the system to new areas, such as previously undigitized departments,
• integrating with external systems lacking communication channels.
Naturally, these areas can occur in various combinations and scopes.
10.
How is data from the ImProdis reported? Can I integrate the ImProdis with my BI system? Can I export data from the ImProdis to Excel, Minitab, Statistica?
ImProdis stores data in a standard Microsoft SQL or PostgreSQL database, which is accessible to users with appropriate permissions. This accessibility allows the ImProdis database to be seamlessly connected as a data source to any BI solution and other tools, including Excel spreadsheets, Google Sheets, Minitab, or Statistica.
11.
Can the ImProdis retrieve data from machines?
The ImProdis serves the purpose of managing production execution and monitoring the equipment. This functionality is achieved with Device Integration Platform (DIP), which acts as a middleware between the deterministic OT world housing the machines and automation systems, and the event-driven IT world where the ImProdis operates. AVEVA System Platform is an example of such a solution, offering integration with both the ImProdis and the execution devices and control systems. This setup provides a wide array of communication drivers available as standard.
12.
How does the ImProdis support production improvement?
The ImProdis serves as a valuable source of accurate manufacturing data for departments focused on Continuous Improvement, Lean, and SixSigma. These departments can leverage this data to identify sources and root causes of losses, plan corrective and optimization actions, and monitor progress.
13.
What indicators are available in the ImProdis? Can I define my own KPIs?
The ImProdis provides information on various indicators, including Overall Equipment Effectiveness (OEE) and its components: performance, availability and quality. The ImProdis’s openness to reporting allows for the calculation of additional KPIs that can be defined in custom reports using the rich data source provided by the ImProdis.
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Complete and submit the form provided on the website.
Within 1 business day, an account manager will call you.
At the scheduled time, you will meet with our consultant remotely.