In the world of production planning and monitoring software, the integration of the MES (Manufacturing Execution System) with the machines on the shop floor is one of the most important aspects that can significantly impact production efficiency.
Examples of integration between office and workshop MES
Below are some actual cases where the integration between the office MES and the workshop can make the difference:
- An urgent production request requires the creation of a new nesting directly on the machine
- Bars in stock have a different length than expected
- Program a tube bender on the machine and synchronize a production plan batch
- Track all production times in sheet metal laser cutting
The advantages of a production management MES that synchronizes office and workshop
High levels of integration involve the fast and automatic exchange of a great amount of information between the office and the workshop. The effects of this synergy translate into measurable advantages for customers:
- Better control over connected systems
- Greater precision in production planning
- Responsiveness in responding to emergencies and unforeseen events
- Flexibility in managing orders
- Increased process efficiency
- Greater ability to use facilities to their full potential
- Better production quality
An optimized information flow improves production control and planning, resulting in increased efficiency, flexibility and responsiveness.
Prometheus, the MES software that connects BLM GROUP machines on the shop floor, guarantees a high level of integration, because it establishes very strong and efficient two-way communication between the office and the shop floor.
Through this technology, not only can work plans be sent to connected machines, but operational feedback and production progress are also collected automatically.
The data exchange protocol is so refined that any changes to orders made on the machine are automatically synchronized in the production plan of the office MES, guaranteeing total traceability of the processes and manufacturing.
There are multiple advantages:
- Save time by eliminating secondary processes like manual production plan updates in the office or triangulating the activities of various collaborators by phone, spreadsheets or USB sticks. Thus, eliminating all risk of error.
- Production management is simplified and more accurate because the office is always synced with production. An easily accessible “digital twin” of the entire production updated in real time.
- Any emergencies, out-of-plan work, operator errors, scrap, material shortages, etc. are always reported to the office. No information is lost, and everything is tracked.
- All data is not only recorded in the database, but also presented in a usable and targeted way to allow managers to make quick decisions based on objective data and accurate forecasts.
In the following paragraphs, this concept is explored in depth with some relevant examples such as unforeseen events or very common needs where Prometheus offers concrete solutions thanks to its synergy with software and production plants.
The Prometheus MES software from BLM GROUP guarantees a high level of integration with tube benders, Lasertubes and other production systems because it establishes very strong and efficient two-way communication between the office and the shop floor.
Example 1. An urgent production request requires the creation of new nesting directly on the machine
Manufacturers receive urgent production requests regularly, which require the production plan to be adjusted.
These requests can be easily managed in Lasertube systems. To save time, the machine operator can interrupt the current batch and produce a new nesting “on the fly” directly from the machine interface, without going through the production MES.
Through the natural interconnectivity between Prometheus and BLM GROUP laser cutting systems, new batches produced on the machine by the operator are automatically reported on the MES production plan, without losing any information.
In particular, consistency will be maintained with the production plan, material usage, machine working hours, new parts produced, the use of the machine and in the general production statistics.
Through the natural interconnectivity between Prometheus and BLM GROUP machines, new batches produced on the machine by the operator are automatically reported on the MES production plan.
Example 2. The stock bar length is different than expected
Prometheus makes creating nesting for Lasertube systems possible, which reduces material waste to a minimum.
But what should we do if for some reason we notice that some or all of the available bars have different lengths than how the nesting was set up?
This situation can occur for a variety of reasons – the bars originally planned may have already been used for other urgent productions (case 1), they may have been damaged, they may no longer be available or the supplier may have delivered bars with an actual length different from the nominal length.
BLM GROUP technology allows the machine operator to manage these situations simply and autonomously as well as automatically report decisions made to the control center.
Office machine synchronization also allows detailed information to be communicated to Prometheus on the status of the processed materials and on the changes made to the nesting.
In the event that the available bars may not be usable with the planned nesting (quantity lower than expected, actual length lower than expected), the operator does not need to request new nesting to be created. BLM GROUP Lasertube systems are intelligent machines capable of automatically re-nesting the part based on the operator's choices. This preserves the total quantity to be produced by including extra bars to be processed or creating partial production based on the contingent material and leaves the rest of the order pending for the arrival of new material.
Information is automatically reported in Prometheus in both cases. In the first case, the extra material used, and the extra time used by the machine are highlighted. In the second case, partial production is tracked and the missing parts are highlighted.
Tube warehouse for the LT24 large-sized tube and profile laser cutting system at the BLM GROUP showroom in Levico Terme (TN), Italy.
Example 3. Programming a tube bender on the machine and synchronizing the batch on the production plan
In tube bending, programming a new part directly from the operator console is common practice. Through VGPNext, the programming software for BLM GROUP tube bending machines, the operator can generate a new order directly from the machine and start production.
Also, in this case Prometheus automatically receives feedback from the tube benders displayed in real time both the operating status of the machine and the production progress in the “Cockpit” monitoring dashboard (also viewable on an external screen via browser) and stores the data in its own database (which can be useful for the final analysis of efficiency and compliance with KPIs).
In a production context with many tube benders engaged in highly flexible production, the synchronization capacity of MES software becomes essential both to have the flexibility to work on the machine in a streamlined way, and to monitor operations with the certainty of not losing track of any data.
Control interface of a fully electric BLM GROUP tube bender.
Example 4. Tracking total production time in sheet metal laser cutting
In the world of sheet metal laser cutting, the great variety of available models and, at the same time, of production programming and management software, means that MES software is often limited to only managing the machine's activity phase, without offering visibility of downtime and accessory times.
The results provided by most MES software on the market tend to be more generic, because they are derived from the inputs triggered by the operations performed on the machine panel (such as "start nesting", "end nesting", "pause") which are limited in nature.
With Prometheus, BLM GROUP has set up optimized communication with sheet metal laser cutting systems, capable of automatically collecting in-depth and detailed data.
To learn more, here is an article that might interest you: A single MES software for tube and sheet metal processing. In addition, Prometheus is able to provide a complete overview of the processed batch and of how the system was used during processing because it accurately records not only the cycle time but also the accessory times during the processing of the active batch, including setup, alarm, waiting or post-production time periods.
For example, accounting for ancillary times allows us to highlight whether the machine was used efficiently, whether the material was prepared well in advance or whether the finished pieces were sorted quickly.
Conclusions
Prometheus offers a level of synergy between machines and the office that allows you to plan and monitor production with a very high level of precision.
This is true even in cases of emergencies, unforeseen events or human errors. The information derived from the activities carried out on board the machine is always automatically reported in the production MES to maximize efficiency, the ability to react to unforeseen events and respond flexibly to customer requests.
Controlling information is the key to enabling the effectiveness of the production processes. This is why the synergy between Prometheus and the connected BLM GROUP systems represents added value and an opportunity to achieve competitive advantages in the market.