RTPT-Real Time Process Tracking System

For Manufacturing EnvironmentSpecific to Tyre Industry

NAME: NEERAJ SRIVASTAVATITLE:COMPANY:

Manufacturing Execution Systems basically fill the gap between an ERP and machines on the floor. The keyword in a system like MITS is "Execution". An ERP system could do all the planning but if it is not executed properly on the floor, it is of no use. It is here that a system like MITS comes into the picture.

• Real Time Process Tracking is a Work Floor Monitoring and Real Time Inventory Tracking System for Manufacturing Environment involving multi stages of production cycle.

• Co-ordinate operations on the work floor to optimize work floor activities.

• Integration of Production Process with Enterprise Systems

• Capture, Process, Validate Real Time Manufacturing Work floor data, to improve the Manufacturing Process by providing timely data and alerts for supervisors and Executives to make Real Time Decisions.

What is RTPT ?

Executive Summary

The new imperative for inventory control systems is to drive profits and facilitate operational performance. In addition to tracking inventories, it’s also necessary to manage them more efficiently in order to increase productivity. Many things must be done to accomplish this objective, however a crucial requirement is the ability to design and deploy a system that includes the planning and management of strategic and operational performances.

Progressive manufacturing companies are looking for ways to streamline their process management, while consolidating their query, reporting and analysis tools to lower costs, simplify end-user navigation and respond immediately to ad hoc requests. In order to achieve a flawless execution of operational demands, a resourceful system that enables multiple critical capabilities is essential.

Continual Performance Measurement – Human efficiency reporting and analysis as well as production reporting and analysis are necessary to provide current accurate measurements of performance and production.Process Improvement – Performance and production tracking to provide the information needed to minimize bottlenecks and waste, as well as increase production.

Efficient Tracking – Automatic inventory tracking, component tracking and inventory location tracking to provide actionable data to managers when they need it.

Integrated Planning and Scheduling of the Manufacturing Floor – Deviations in scheduling should be managed in a timely manner to increase production efficiencies and effectiveness.

• Most significant area of value creation.

• The shop floor is the area where the purchased raw material is transformed into that special finished product.

• The pursuit of improvements is continuous, and often revolves around product quality, production speeds, machine utilization and labor productivity.

• Customers demand first-rate quality, lower costs and rapid delivery.

• Global competition requires manufacturers to produce at an unprecedented pace, with reductions in defects, waste and cost.

• Production schedules become outdated just minutes after they arereleased due to changes in customer demand, material availability and labor.

• Machine operators struggle to understand the sequence of work tobe performed and the availability of component materials needed to complete the work.

• Eliminate the unexpected from production operation.

• Foresee issues before they became real manufacturing problems or detect exceptions the moment they occur…instead of spending hours walking the production floor scanning for problems.

• Do away with the traditional paper-based shop floor environment and create real-time controls to streamline production.

• Mobile Inventory Tracking System (MITS) is a comprehensive and highly customizable Manufacturing Execution System (MES) which covers all the stages of the Tire Manufacturing process from Mixing till Final Finish.

• MITS provides the management and synchronization of production tasks with material flow, labor and machine resources to achieveoptimal operating performance and customer satisfaction.

• MITS can drastically improve productivity throughout the entire manufacturing process via the reduction of non value-added activities, an increase in data accuracy and enforcement of operational and regulatory procedures.

• Eliminating waste throughout production – overproduction, waiting, unnecessary inventory, defects.

• Reducing labor training and production costs

• Driving continuous improvement

• Helping ensure items are built to specified product quality

• Adhering to customer & regulatory requirements

• Gaining real-time visibility into the shop floor

• Capturing detailed product genealogies

• 1. Import of core data:• Items – all unique raw materials, semi-finished and finished

goods• Bills of materials – the inputs required for making a semi-

finished or finished good• 2. Work Order Import, Prioritization and Dispatch to the floor.• 3. Recording Production Activity at the work cells

– Tag printing with barcodes on Mixing, Calendar, Extrusion, Stock Prep, Beads and Slitting machines.

– Real time WIP inventory tracking – Production Counts for PLC enabled machines.– Machine set-up, running and downtime, along with

downtime reason codes – Components scrapped, along with scrap reason code

assignment– Recipe verification and validation– Generation of payroll data for hourly employees at the end

of every shift.

• 4. Capture complete product genology including – Who made it.– With which machine(s)– Which other products were made on the same machine in

a given timeframe (in case of defect)– Which materials are in the product– How much scrap was produced– Data to determine cost to make each part– Multi-level lot tracking

• 5. Performance Analysis– Schedule Vs Actual Comparison– Scrap Reporting– Machine Utilization– Operator efficiency– Component Usage

• 6. Events and alerts – monitoring mechanisms that alert supervisors and managers to unexpected events, such as underproduction, defective parts or slow production times.

• Accurate job costing and tracking: – MITS captures labor time, machine data, components used and

output material completed. – These are all critical in helping calculate the true costs of your

production. – Having this data helps you identify areas for improvement and

allows you to continuously measure performance against those improvements.

• Reducing labor costs: – MITS tells each shop floor operator exactly what to do next. – This helps them prioritize and their work, preventing mistakes and

rework along the way. – Every operator or crew using MITS records the time for each work

order, allowing supervisors and managers to evaluate performanceagainst standards.

– This allows management to better incent and reward the work force, as well as understand when to update the standards to push even better productivity.

• Decreasing cycle times: – MITS provides intelligent work dispatch, accurate production

execution, and seamless coordination between material handling and the work cells.

– All of this leads to streamlined material flow and lower cycle times.

• Enhancing quality: – By helping to ensure that all necessary data is collected, and

validating that the results meet appropriate criteria, MITS drives production reporting and quality inspections.

– This leads to fewer defective products making it through the process.

• Improving customer satisfaction: – All of the above lead to the most important benefit of all:

Pleasing your customers. – By using MITS, you can deliver your products with higher

quality, lower costs and better on-time predictability.

• Outstanding system configurability: – MITS is highly adaptable and flexible solution that allows you

to adapt your software quickly and easily to changing business environments without excessive costs or disruption to ongoing operations - and without modifying source code.

End of every shiftNot availableMachine Uptime/Downtime Data

End of every shiftNot available

Detailed Operator/Tire Builder production data with Operation Charge and Operation Number assignment

Real-time availability Not availableLot Traceability - Tire Defects in Final Finish back to Mixing

None 3-6 times/monthBuild Out losses due to Build Out stock being run on a Stock Prep Machine

End of every shift Not available

Tire Production (Standard Rate vs Actual Rate per Machine)(Data for Industrial Engineering for analyzing

machine efficiency)

Real-time availability 15-30 mins (only at the end of shift)Scheduled vs Actual Production Data

Real-time availability 30 - 60 mins/ShiftGreen Tire Inventory

Real-time Availability or (15-30 mins using Scanners)

90 - 120 mins -ManualWIP Inventory Counts/Shift

10 - 15 mins/shift45-60 mins/shiftHourly Payroll Approval/Shift (By Shift Supervisors)

3- 5%4 - 6%Scrap Material

75-120 mins100-150 minsMachine Downtime (Tire Building Machines)

With MITSEarlierFactors of ROI for Tyre manufacturer

2000 plus employee25,000 tyres/dayProduction

Continental Tyres, Mount Vernon, ILCompany:

Benefits of MITSEnhanced and Enriched User Interface: MITS provides an enhanced and enriched user interface in handheld/mobile devices.

Customizable Events and alerts: The system is easily customizable to include any events and or alerts based on manufacturing environment requirements.

Collect Relevant, Accurate and Actionable Data: MITS only captures data that is relevant to the actions to be carried out. Since data capture procedures go through different Business Rules implemented at different levels, the data is thoroughly validated and accurate. As data is collected, only the action(s) required can be performed on the captured data, and the dissemination of reporting and analysis documents can be strategically and strictly controlled.

Pedigree Tracking: System capture of the entire lifecycle of a product and or its components is available at the touch of a button.

Item Tracking of Human and Machine Activity: MITS provides an extensive audit trail of all human and machine activity.

External Device Integration: MITS provides an interface to the system controller to capture the controller data for interpretations. Integration with barcode printers, label vendors for tagging and RFID scanners is straightforward and standard.

Complete Tracking System: Assorted aspects of the manufacturing process can be tracked through various stages of the component life cycle. Tracking of item life cycle, process and workflow, human resource activity on an item and recipe for the creation of the item is provided. Items can be tracked at individual and or container levels.

Online Offline Connectivity: MITS has full functionality both online in wired or wireless networks as well as offline when a network is not available to the external devices. Data can be synchronized periodically when required, preventing data loss and avoiding disruption of production operations.

Conclusions

A modern inventory tracking system provides a company the means to gain a clear, accurate and timely understanding of its operational processes. When implemented properly, it enables the modeling, measuring and optimization of all production resources. It gives managers the tools they need to direct and achieve maximum operations and production performance.