Production Automation

Solution description

Our goals:

- Separate Business Manager, Production Manager and Operator interfaces, providing the data they need in intelligible forms

- Fully supporting Dynamics AX (Axapta) to Material Requirements Planning (MRP II) interchange

- Automated Data Collection systems including Bar Code printers & scanners, RFID transceivers and other 3rd party devices accompanying processes on the production line

- Axapta enhancements concerning streamlining production & transport orders, direct Axapta to PLC (Programmable Logic Controller) communication

- Complete Track&Trace with the use of automatic ingredient weighing systems, wireless operator terminals with lightweight Axapta Clients, registering in database every item’s location and state during each production phase

Client Benefits:

- React instantly to last minute production schedule changes due to advanced monitoring by Automated Data Collection (ADC), PLCs (Programmable Logic Controllers) and notification systems

- Interfaces for business managers – overall or detailed summaries and reports with efficiency indicators, production costs for each machine, shift or human resource

- Interfaces for production managers – insights into feedback from the production floor for personnel and machinery capability and functionality drill down

- Interfaces for operators – real time monitoring, enabling production error prediction and detection mechanisms

- Acquire greater efficiency by binding various Axapta functionality and reducing the amount of user interaction cycles

- Track & Trace with the use of Bar Code labeling, RFID, wireless devices

- Minimize assembly losses by scrap reuse processes

Case Study:

Our projects at a bakery with a throughput of over a hundred thousand buns a day included a thorough production automation and optimization by means of controlled flow of materials and work.

To clean up, estimate, plan and control production processes our customer needed to be aware of the production orders processing, machine and human efficiency and at what speed the warehouse ingredients were being used. Achieving those goals was not only a matter of placing monitoring, ingredient weighing and bar code labeling systems on the production line, but also integrating them and enabling an uninterrupted communication with Axapta.

The solution:

5 Steps of the process:

1. Production Order sent to Production Manager.

2. Data from the scales is registered in Axapta.

3. Axapta orders printing of pallet Bar Code.

4. Bar Code is scanned and registered in Axapta.

5. Axapta generates pallet transport.

When a production manager creates a production order, Axapta counts how many ingredients will be needed and in what quantities. The data is transmitted to a terminal, which is connected to a scales in the production hall. An operator places the ingredients on the scales according to the order and quantities printed on the terminal screen.

If Axapta accepts the inputted data (correct order and weight) then the dough production order is initiated and the supply levels in the warehouse are updated.

BAR CODE printers & scanners:

With each pallet completed, Axapta sends a label print order to a printer connected to another terminal on the production line. A single label contains the pallet’s individual number and bar code. The label is automatically attached to the pallet after packing. The machine operator scans the bar code on the pallet. Axapta then marks the production as finished and generates a transport order for the pallet.

Again, human interference is only focused on checking, whether the machines are working properly and recording the significant production stages into Axapta.

AUTOMATED Data Collection (ADC)

We managed to extend Axapta’s functionality to a maximum by attaching various 3rd party devices (bar code scanners, RFID receivers) accompanying production processes on the production line. Those devices send signals, notifications and other data directly to Axapta where they’re being instantly recorded and processed.

With that data Axapta allows you to reach real process engineering by fully streamlining the production life cycle and providing a real-time visibility of the processes. In that way Axapta becomes your powerful tool for flexible management control.

With the use of Microsoft Axapta we are able to provide a full Track and Trace control, which is required by the EU law. In the area of Tracking we define routes and production lines including elementary stages of the production. Tracing is enabled by the clear and automatic assignment and identification of BOM. In that way Axapta traceability data flow is concurrent with a customizable Supply Chain Management. This system keeps an eye on the safety of the production and individually recognizes the machines, shifts and employees responsible for production of each item.

Operator, Maintenance and Manager INTERFACES:

At all stages of the WIP (Work In Process) authorized employees will have access to proper interfaces to monitor the material and work flow. We provide the operator’s interface to control the proper work of production line processes. The manager is granted an overall engineer interface to view throughput of the production line, summarize the efficiency of a work center (machines, employees) and create detailed reports based on the Axapta collected data.

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