MES

Summer heat can take its toll, as we have recently experienced firsthand. But what about people working physically in a production hall where machines can heat up to over a thousand degrees Celsius? One of the largest iron foundries in Europe – Vald. Birn – operates in such conditions. Vald. Birn is a Danish company with a century-old tradition; its origins date back to 1893. Currently, the enterprise employs 1,000 workers across four factories, producing up to 3,000 different assortment items in the field of metal castings. Their clients include key automotive brands such as Volvo and Mercedes. The metal products themselves – often critical from a safety point of view – must absolutely meet rigorous quality requirements. In such a demanding and (especially during the summer) extreme environment, there is no room for errors. That is why the digitalization of production turned out to be crucial. Replacing Binders with an IT System For many years, production management at Vald. Birn relied on sheets of paper. Leif Jensen, the company’s Financial Director, admits that “sticky notes and kilometers of binders” piled up everywhere on the desks. This significantly slowed down the documentation process and also caused limitations in data access. Furthermore, the company made the decision to completely overhaul its ERP system. However, it turned out that the previous program was too much of a challenge for the operators working directly on the foundry floor, who were not accustomed to handling complex IT interfaces. Therefore, they needed something more intuitive to use. An MES System Resistant to 1500 Degrees To solve this problem, in parallel with the implementation of the main ERP system, the company launched the Operator MES software. Currently, it acts as an agile extension of the Infor M3 business system in a harsh production environment. Block Quote The implementation itself was a massive logistical undertaking. Inside the foundry, among crucibles heated to 1500°C and heavy machinery, a staggering 170 terminals were successfully deployed. The analysis department, located directly on the production hall, became the central point to which samples flow continuously via a special pneumatic tube system. In the laboratory, the composition of 20 different alloys is verified (including the content of elements such as titanium, lead, copper, and zinc). All results of these measurements immediately go to the Operator Platform, where they are automatically linked to specific customer orders. How to Achieve a Defect Rate Below 2% The management of Vald. Birn considers the implementation of the Operator system a “great success from day one”. The project brought results that permanently revolutionized the daily functioning of the foundry. Among the greatest benefits the company noticed were: Paperless approach – the paper documentation system was completely eliminated. Instead, the registration of orders, processes, and quality measurements was automated. Full Traceability – by ensuring strict quality control, the defect rate (scrap rate) was maintained at a level below 2%. Error identification – this process was significantly simplified and accelerated, facilitating an immediate reaction to irregularities. Audits – the company reached a completely new level of process documentation. This resulted in an official commendation from the Bureau Veritas auditors during certification. Intuitiveness That Builds Data Discipline Importantly, the success of the project was determined not only by the technology itself, but by its reception by the employees – including those who were not previously used to IT solutions. Vald. Birn operators received a precisely personalized interface. Only data and registration options strictly corresponding to their current tasks appear on their screens. The system gained tremendous appreciation, and today the employees themselves actively submit requests for new improvements and shortcuts. They understood how important correct documentation is, which translated into tremendous discipline in entering information into the Operator Platform. This is also proven by the implementations carried out in other plants of the group, including Kockums. Block Quote Thanks to the combination of advanced MES technology with intuitive operation, Vald. Birn proves that full quality control is possible even in the hottest industrial environment.

“If you can’t measure it, you can’t improve it.” It is hard to disagree with the words of the CEO of one of the factories we have worked with. Without precise data regarding the time and money spent on production downtime, it is difficult to maintain control over the performance of your machinery park. Moreover, simply having an ERP system will not solve the problem if the production floor lacks MES-class tools. True control over production begins with properly defining downtime categories. It is also necessary to distinguish between key performance indicators – OEE and TEEP. OEE and TEEP Indicators – What Do They Measure and How Do They Differ? Understanding the current equipment effectiveness at the level of a production shift requires the use of appropriate indicators. In the case of the Operator Platform, the Machine Status Monitoring module allows for an in-depth analysis using two key measures: OEE (Overall Equipment Effectiveness) – This indicator is based exclusively on the scheduled production time. It shows the utilization of a machine during the time it was actually scheduled to run. OEE consists of three components: availability, performance, and quality. If a machine runs for one shift (8 hours) and achieves ideal parameters during this time, its OEE will be 100%. Thus, the indicator allows not only for the optimization of production but also for the identification of losses during the shift. TEEP (Total Effective Equipment Performance) – A measure that takes into account the total calendar time – 24 hours a day, 7 days a week, 365 days a year. Therefore, it shows the maximum potential of the factory, taking into account so-called planned losses (e.g., holiday breaks). Because of this, a machine that runs for one 8-hour shift a day will have a TEEP of only 33%. This is due to the fact that it is turned off for the remaining 16 hours. Why is this so important? OEE shows where we are losing money due to breakdowns, changeovers, and micro-stops. TEEP, on the other hand, reveals the hidden capacity of the factory. It often proves that instead of spending millions on new production lines, it is enough to invest in an additional shift or optimize planning in the ERP system. How to Properly Categorize Downtime? Before we start analyzing the smallest micro-stops, the main groups of line stoppages must be properly defined. Implementing a system like Operator MES forces an organization to structure its losses. The foundation is a clear division into planned and unplanned downtime. Planned downtime includes machine changeovers, scheduled maintenance, or employees’ breakfast breaks. Unplanned downtime, on the other hand, includes mechanical failures, speed losses, and shortages of production materials. Thanks to the Operator Datalogger module, connected to terminals on the shop floors, the system gains full context: Cause tree – Downtimes are categorized hierarchically, which allows for the analysis of the sources and frequencies of individual events. Context from the operator – Using a terminal, the operator manually assigns a detailed cause code. They can also add notes, which may concern, for example, the machine operating at a reduced speed. The truth about changeovers – The system precisely separates actual production time from machine setup time. This is often the largest area of hidden losses in manufacturing plants. A Step into the Future with AI Once manufacturing plants master the basics – defining downtimes and starting to measure OEE and TEEP – they can reach for the most advanced tools. The Operator OEE solution, integrated with the Manufacturing Intelligence platform, offers support at the level of artificial intelligence. Machine learning algorithms provide optimization recommendations based on historical data and performance patterns. The ACIP (Automated Continuous Improvement Process) mechanism uses AI to predict potential quality problems and anomalies in machine operation. Are you looking for a technology partner who can help with the proper implementation of an MES system and a precise downtime grid? We encourage you to contact us and schedule a software demo.

The occurrence of defective items in production is an everyday reality for every factory. The key to maintaining profitability is not only preventing errors, but also the ability to properly manage them when they do occur. This process is supported by modern MES (Manufacturing Execution System) class systems, which enable advanced defect handling. Thanks to this, operators can classify and manage non-compliant products without interrupting ongoing production. Precise Classification of Defective Products Traditional systems often force employees to simply mark damaged parts as “defects”. This, however, blurs the picture of what is actually happening on the production line. This approach is prevented by Production Execution in the Operator platform. The Production Execution module is an MES terminal that becomes a communication channel between the production hall and the system. In addition to comprehensive production reporting capabilities, the terminal enables advanced waste reporting (so-called outsort management). It supports the disposal process while simultaneously allowing for the introduction of all corrections, performing repairs, and handling so-called re-work products. The result? Operators gain the ability to accurately determine the causes of errors. Because of this, subsequent quality analysis becomes a solid foundation for minimizing material losses. 5 Paths for Dealing with a Defective Product Managing defects on the fly requires a flexible approach. The Operator system offers five main classification paths for units that require additional intervention: Direct Repair – a feature that enables direct repair of a defective part without interrupting ongoing production. The operator can repair the product on the spot and immediately return it for further processing. Repair – involves repair actions at the production workstation, but they are performed at a later time. This can occur, for example, after the completion of the current production run. Rework – otherwise known as reworking defective goods. This allows you to modify products and give them a new material code or create entirely new products. Scrap – the final classification of a product as waste that is unsuitable for further processing or repair. By-products – these are elements or semi-finished products created during the manufacturing of the main product. Parts classified this way can be effectively utilized in future production processes. Defects on the Fly – How to React Quickly? When we free operators from the necessity of working at stationary terminals, quality management becomes much faster. The Operator Mobile App enables the registration and classification of production waste directly at the workstation. In turn, the Quality Control module guarantees immediate quality monitoring at all stages of production. Mobile solutions also facilitate access to data on quarantined products. Thanks to this, it is possible to report test results and streamline their release process. Why Is This So Important for the OEE Indicator? Entering the causes of rejections and errors in real-time provides invaluable information for the entire factory. It allows for a comprehensive analysis of production quality on an hourly or shift basis. Furthermore, the precise identification of defective batches will allow for targeted product recalls and cost reduction. Treating quality defects as an inherent element of the process and implementing tools to manage them on the fly is a huge step towards Industry 4.0. Instead of stopping the entire line, employees can act in a planned manner. In the future, the data collected in the MES system will allow for the elimination of bottlenecks in the area of quality. Do you want to check how such a solution will work in your factory? If you are in the process of looking for a system to optimize production, we invite you to contact us and schedule a demo.