Making Rubber and Plastics Manufacturers more responsive with Epicor Mattec MES

© 2015 Epicor Software Corporation

Making Rubber and Plastics Manufacturers more responsive with Epicor Mattec MES


● Why MES?● Epicor® Mattec® MES™:

what it is, what it does● How it works● Success stories

Contents


Why MES?


● Plastics and rubber● Fabricated metals,

metal parts● Automotive parts,

components● Electronics● Medical moulding,

instruments● Printing

What industries and verticals is Mattec MES softwaredesigned for?

● High-speed print● Extrusion● Blow-moulding● Die-casting● Metal extrusion● Cable manufacturing● CNC machining

(Computer Numerical Control)

● Assembly● Containers● Food● Pharma

● Injection moulding

● Thermo-forming

● Automated assembly

● Metal-forming


Quality, responsiveness and capacity are key objectives

Source: “Weaving The Digital Thread 2014,” LNS Research

Top operational objectives


● Manual/paper based time-sheets?● Epicor ERP – MES system

functionality?● Scanning bar-codes?● Direct from machines?

How Do You Collect Shop Floor Data?


Why are our machines not

running consistently

well?

What can we do to boost

quality and on-time orders?

Why are some shifts better than

the others?

We’re a “Lean” shop … why

aren’t we getting better?

OEE got better … but nothing else

did.

We can’t take on more

business unless we buy more

machines.

…but the ERP system says we can do all these orders today…

Production problems cause

schedule conflicts.

Why are we always shipping

orders “last minute”?

Are you asking these questions?


Consequences of a disconnected shop floor

Disconnected data sourcesPoor operational visibility

Disconnected job scheduling Delayed information from equipment

Yourobjectives


Further (cost) consequences of a disconnected shop floor

Late shipments

Higher shipping costs

Unhappy customers

Penalties, fines etc


The business case for MES software

Source: “Metrics that Matter,” LNS Research and MESA Study 2014

Average annual improvements in:


Epicor Mattec MES: What it is, what it does


An Automated Manufacturing Execution System

Mattec MES software manages:● Production monitoring● Process monitoring● Automatic part qualification● Dynamic plant floor

scheduling● Energy monitoring● Visibility, reporting and

analytics: plant and enterprise● SPC & SQC

So you can:

access accurate data in

real time

start asking the right questions

make well-informed

timely decisions


● Gather data directly from equipment via M2M and computer interfaces

● Monitor machines automatically to analyse production and performance 24x7

● Operators can easily add data to provide additional insight

Same Machines, Increased Production


Mattec MES software helps you...

● Increase capacity without adding assets

● Improve throughput and reduce downtime

● Improve quality/reduce scrap● Improve overall OEE


How it works


The old way…

Performance and loss analysis printed

for review

Production plan generated by ERP system

Product count, scrap count, scrap reasons, downtime calculation and downtime reasons gathered manually

Data entered into ERP system manually

ERP System

Scrap

Scrap

Schedule adjustments delivered manually

Schedule adjustments delivered manually

Production

Product count, scrap count, scrap reasons, downtime calculation and downtime reasons gathered manually

Performance and loss analysis printed

for review

Production


A new approach that complements your ERP system...

Information viewed and inputted in real time

ERP System

Production plan

Schedule and production updates

• Production plan• Schedule changes• Product count• Scrap count• Scrap reasons, Downtime• Downtime reasons

Real-time exchange of information

Real-time exchange of information

Mattec MESSystem


How real-time integration with ERP software works

Scheduled Epicor ERP Import Process

Input Directory for Mattec MES Export Data

Scheduled Mattec Automatic Data Export

Process

ERP Export to Mattec Batch Process – can be manual or

automatic process

Output Directory for ERP Export Batch Data

Scheduled Mattec Automatic Data Import

Process

Epicor ERP/Mattec MES System Integration Data Flow

Data that is Exported from the Mattec MES system• Labour Details• Labour Completed Parts and the quantity completed• Labour Equipment counter associated with reported

quantities• Scheduling parameters, including company and job data,

operation data and production start and end dates

Data that is Exported from the Epicor ERP system• Scrap Codes• Indirect Downtime Labour Codes (Downtime Codes)• Resources marked as Tools (Tool IDs)• Manufactured Parts (Manufactured Items)• Production Methods and Operations (Process Sheets)• Production Jobs• Preventative Maintenance Jobs• Material Parts (Materials)• Manufacturing Employees (Operator IDs)


Providing value across the business

Mattec MESSystem

Plant analytics

Plant management

Enterprise analytics

Top floor (corporate)

Performance analyticsReal-time production displays

Spc & sqcVisual, dynamic scheduling

Energy monitoring

Plant operations

AIUShop floor touchscreen hmi

Plc, opc, opc connectorReal-time production displays

Real-time metrics

Shop floor


Success stories


Success Story

HERR GmbH optimises product at new site with Mattec MES software to safeguard growth

“Thanks to the Epicor Mattec MES software a quick overview of our real production is possible at any time. The optimisation potential is enormous.”

Cornel Herr, General ManagerHERR GmbH

Business Benefits

30% production increase

Improved quality and timelines

The Mattec MES solution is the core application for the entire production process


Success Story

Epicor Mattec MES software drives continuous improvement at Johnson Controls

“We used to run 3-4% scrap. Last month we were down to 1.37%. You can’t get much better than that; that’s world-class and is largely attributable to the Epicor Mattec solution.”

Dave Rose, Quality EngineerJohnson Controls

Business Benefits

Decreased scrap to 1.37%

Decreased machine downtime by 3.1%

13% improvement unit manufacture cost

8% increase in overall productivity

50% reduction in job changeover time

Annual cost of quality reduced by $600,000


Plano Molding uses Epicor Mattec MES software to tackle plant efficiency

“The shop floor insights that Mattec software provides helps our team drive bottom-line growth. Real-time planning and scheduling insights with Mattec software allows us to respond to our customers faster.”

Tom Dimick, Director of ManufacturingPlano Molding

Business Benefits

Drove bottom-line growth with real-time shop floor insights

Success Story

Achieved $700,000 savings in scrap improvements

Enabled real-time visibility into OEE, scrap, and cycle times

Inspired continuous improvement initiatives and teams

Improved customer experience as a result of better planning


To summarise…

With Epicor Mattec® MES™ software

Increase product, from your existing machines, using

real-time, accurate data... …helping you ask the

right questions and make well-informed and timely decisions


Thank you

Interested in learning more?Visit: www.epicor.com/uk/mes

Making Rubber and Plastics Manufacturers more responsive with Epicor Mattec MES

Software

Transcript of Making Rubber and Plastics Manufacturers more responsive with Epicor Mattec MES