Test before invest

Test digital solutions for your factory for free as part of the European EDIH initiative

A free trial of solutions to automate machine monitoring is an offer from Imfactory, available as part of Hub4industry’s EDIH project.

Hub4industry is a consortium formed by Kraków Technology Park, ASTOR and T-Mobile Poland, AGH University of Science and Technology in Kraków, Kraków University of Technology, as well as experts from BIM Klaster, Łukasiewicz Research Network – Kraków Institute of Technology, Entra Group, ReliaSol and ICsec. Hub4industry helps Polish companies evolve into the factory of the future and increase competitiveness by implementing modern technologies and solutions. As part of ASTOR Group, ImFactory also has a stake in this project.

About the project

As part of the European Digital Innovation Hub (EDIH), SME companies can take advantage, free of charge, of comprehensive consulting in the area of Industry 4.0 – from concept to implementation. They have the opportunity to see live technologies adapted in leading domestic and foreign companies, as well as take part in training courses and workshops to prepare for planning and implementing sustainable changes.

Target group

The offer is aimed at all companies – especially manufacturing.

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Customer values

The purpose of the service is to present the opportunities and practical verification of the benefits that the company can achieve through:

Digital production management system
Overseeing the efficiency of production outlets
Implementing the automation of data and information flow between supervision and production outlets and the possibility of eliminating the circulation of paper-based information
Current and accurate information about the availability and performance of the machinery fleet and the main causes of production losses due to unplanned downtime, registration of so-called micro-downtime
Successively acquiring knowledge and competencies related to production indicators (KPIs) and system performance to build awareness among staff and management about digital production management systems and Industry 4.0
Implementation of an open standard in terms of data collection as well as its analysis allowing for later expansion with new functionalities
Simple expansion of the system with additional production lines/sockets.Implementation of an open standard in terms of data collection as well as its analysis allowing for later expansion with new functionalities; simple expansion of the system with additional production lines/sockets

The service reduces the absorption time of 4.0 solutions in the factory and increases their availability for companies for which the investment risk is too high. It ends with a report of automatic monitoring of the work of the studied machine, e.g. KPIs, causes of downtime and others for a selected period of time with a print screen. The customer sees it online.

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Service description

The service consists of a pilot implementation of a platform for monitoring the operating status of selected machines (1-5 outlets), using operator panels to report complementary information. In addition, software will be launched to collect data and enable current and periodic analysis of machine park availability.

Implementation follows a proven test process and includes:

Provision of operator panels to enter additional information: shutdown status (planned stoppage), changeover with identifier, failure with identifier, i.e. causes of downtime;provision of operator panels to enter additional information: shutdown status (planned stoppage), changeover with identifier, failure with identifier, i.e. causes of downtime
Provide a cloud-based database and analytics platform to record and present time runs and generate dedicated reports showing selected production metrics
User training

The service is implemented using the ImProdis efficiency system from ImFactory.

The ImProdis MES system offers a comprehensive set of functionalities that effectively support the flow of information at each of the three levels of company operations:

• Production
• Operational
• Managerial

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.

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.

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.

ImProdis MES

The ImProdis MES system offers a comprehensive set of functionalities that effectively support the flow of information at each of the three levels of company operations:

Production
Operational
Managerial

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.

Testing Process

The service is delivered according to a proven testing process and includes:

Discussion with company management regarding business challenges and expectations related to the quality of the planning process
Preliminary analysis of planning and production processes to define the scope for the pilot implementation
In-depth analysis of the selected pilot scope, including defining:
- production resources, BOMs and product routings, constraints considered in planning and optimization
- data required for import into the APS
Development of a spreadsheet for importing APS data
- Integration of the APS with ERP and/or MES systems is possible if the company provides properly prepared data within them and grants access via an SQL database
Configuration and launch of the APS pilot instance in the cloud or on server resources prepared by the client
Training and ongoing support for planners regarding data import and basic APS operation within the scope of the pilot objectives
Discussion of pilot findings with planners
Presentation of pilot findings to management, referencing the business challenges and expectations defined at the outset
The service shortens the adoption time of Industry 4.0 solutions in the factory and increases their accessibility for companies for whom the investment risk is too high.

Objective

The objective of the service is to present capabilities and practically verify the benefits the company can achieve by:

testing APS software capabilities on the model and data of the company where the pilot is conducted
drawing conclusions regarding operational and business benefits that APS can bring compared to currently used planning/scheduling methods
identifying actions required for the final APS implementation

The service concludes with a report assessing the feasibility of launching digital production planning support.

Target Audience

SMEs from any manufacturing sector wishing to improve on-time delivery, reduce changeover times, and minimize operational costs.

Duration

Estimated time to launch one PoC – 4–8 weeks.

O ImFactory

Factory Sp. z o.o. [ImFactory for short] is a subsidiary, part of ASTOR Group, which was established on the foundation of an in-house competence center, MES Solutions by ASTOR, specializing in MES systems. After 6 years, due to the rapid growth of the market for digital solutions for streamlining production processes in plants and factories, the company is expanding its activities in this area. It provides Central IT Systems for manufacturing, which include MES (Manufacturing Execution System) class systems, APS (Advance Planning and Scheduling) production planning systems and IT system integrations (Enterprise Service Bus). The team is made up of Engineers – specialists in IT systems for industry, project managers and consultants in technical and process consulting, which in effect allows manufacturing companies to comprehensively digitize their processes and improve them, thus increasing the value of enterprises. As of 2021. ImFactory is also the AVEVA MES Competence Center, which supports the development of the MES market in Central and Eastern Europe.