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Production management system
All manufacturing processes are conducted using this HDF-developed IT system, which uses individual modules to support successive production stages. Computer-assisted manufacturing not only optimises current activities, but also facilitates the planning of changes to activities.
The starting point for the client’s custom IT system was to develop a production management program encompassing all company processes. This required a thorough analysis of all factory operations subject to established procedures. The joint preparation of detailed manufacturing process documentation with client representatives led to the creation of an application architecture which fully reflects all processes. Individual modules are responsible for the implementation of successive stages of manufacture. This starts with organisation of the warehouse, including process and inventory control, through supporting all stages of line production, and ends with production quality control and handling of the finished product warehouse, which delivers to company customers.All phases of manufacturing are closely supervised by our IT system. The whole process starts with receipt of raw materials by the warehouse. Materials have a specified expiration data determining their suitability for use. Computer-assisted handling of the warehouse helps optimise their use, avoiding the expiration of inventory. The material is sent from the warehouse for a process of vulcanisation, whose parameters are also monitored by the production management software. After this operation, processed material must undergo a process of resting, the length of which is supervised by the appropriate application module. After this period, the prepared material goes to the production line, where semi-finished products are manufactured. The plant manufactures rubber hoses from pre-made tubes which are moulded according to appropriate parameters.
After this process, the hoses are sent for cleaning, where all undesirable manufacturing residues and deposits are removed. The IT system supports employees in the receipt and quality control of items coming from the washing stand. This is done by displaying images of individual hose types on a computer screen, allowing inspection and segregation staff to compare newly manufactured hoses to a standard, and sort them appropriately before passing them on to further production stations. This IT solution not only effectively supports quality control, but also helps employees to avoid confusion between visually similar components. Product descriptions of almost 50 parameters are entered into the system through a user-friendly interface.
The semi-finished products are sent to the warehouse, where the system sorts them by particular customer using the FIFO method (First In, First Out). From there, they are transported to appropriate assembly stations, where finished products are prepared. At this stage, production involves third-party components, whose warehouse is also monitored by the system via a kanban module. After completion of the finished product, it undergoes another quality assurance (QA), assisted by the computer system. Products which pass the test go to the final warehouse, from where they are subsequently delivered to the customer.
The application was developed in .NET technology and uses Microsoft SQL Server. The production support system is operated from multiple workstations by employees equipped with various devices: barcode scanners, handheld terminals (mobile computers), industrial touch screen panel computers and standard PCs. HDF was responsible not only for the development of the IT solution supporting production processes, but also for the provision of all requisite equipment for system implementation, which included equipment from various manufacturers, such as Psion, Zebra and Motorola Solutions.
Existing client equipment was also employed in the new solution, thus optimising use of hardware resources. The supplied equipment was covered by specialist maintenance service, which is carried out regularly in the event of any problem with device operation.
The solution allows for an unlimited number of label printers to be remotely operated, with Wi-Fi communication between individual system devices. Each user of our production management program is provided with a unique identifier to log into the system. Specific permissions granted by the administrator to individual users and groups give them access to only such information and features as are necessary for the fulfilment of their duties. In addition to its pure manufacturing features, the designed IT system also supports administration by calculating employee working hours and bonuses.
The warehouse handling feature supports the preparation of orders by specifying material requirements, which are then immediately transmitted to employees involved in their supply. Modules responsible for production planning allow product manufacture quantities to be precisely determined, converting those quantities into demand for raw materials and third-party components used in the process. This has optimised the warehouse stock process, giving the company uninterrupted access to its essential materials, while rationalising inventory levels. Stock levels are maintained at the precise level needed to manufacture the predefined quantity of goods. All buffer stock is controlled by the system, and it is possible to carry out their full or partial stocktaking at any time in order to check actual stock levels and compare them with the latest production support system data. Should the need arise, the application has been equipped with an expedited shipping handling feature for faster delivery of shortfall components.
Implementation of the solution in our client’s plant significantly improved the flow of all raw materials, semi-finished products, external components and finished products. The quality control performed at every stage of the production process has contributed to a reduction in production errors resulting from the poor manufacture of goods and employee mistakes. In the case of a complaint being lodged for a finished product it is possible, on the basis of the assigned identifier, to determine from exactly which batch of raw material it was made and how exactly the production process proceeded. The advanced reporting system supports the ongoing or periodic optimisation of all activities, for effective correction of unsatisfactory indicators by the management. With full control over the work of employees in the plant, the party ordering the production management software is now able to remunerate employees on the clear basis of their work, and to implement a transparent bonus system.
Our client is Europe’s largest manufacturer of flow systems used in the automotive industry. The software developed on request is used in a Polish factory. The system is designed for continuous, three-shift operation. The solution is operated by approximately 500 employees.