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The effective providing of the information is an important condition for all companies, but at least a major success factor. Amid the economic difficulties, the business processes have to run under full control on operational levels, and leader levels too. In the production is particularly important to show the Informations (weekly, monthly, etc) about the workers and the production processes (materials, machinery, productivity), as well as their context.

The TPC is an integrated system, which collates these Informations and forwards to the users. With monitoring of the shift, the production/plant manager can get a full overview of the manufacturing processes; moreover there is a possibility to immediate reaction.  What are these Informations?

  • utilization of production machinery

  • the current availability of stock

  • material flow and production machine activity (the whole production process)

  • monitoring of staff activities and working times

 With the four - linked to each other – subsystems of TPC, the Informations above (and their changes in time) can be monitored on-line and presentable with reports, or management dashboard. The system contains four separate modules (as you can see below on the picture) which can be implemented step by step too.

Figure 1. TPC system overview



Figure 2. TPC Network

It is common in the subsystems that their implementation is simple and requires no special pre-conditions: the system elements (hardware: workcontrol terminals, scanning units; software: communications services, management dashboard) can be easily integrated into existing network infrastructure. In the following, the modules and subsystems (their functions and benefits and usages) of the TCP system will be introduced in more detailed.

Productivity Analysis Module

The productivity analysis module designed to collect and make available all the Informations what necessary to monitor and analyze the status of machines into the production. The system continuously monitors and saves into a database:

  • Downtime of machines

  • causes of downtime

  • the produced quantity

  • the number of faulty products

Based on these on-line (continuously updated) data you can get actual overview about the productivity, about situations that require immediate intervention directly on the terminal of the machine, or in daily weekly, monthly reports.

Figure 3. Productivity analysis module

To use the system you need a workcontrol terminal (connected to TCP/IP network). It is connected to the machine in the production and automatically monitors the operation of the machine, so you can get a real overview to evaluate a period.

The content of the software package

 

Communication service program to receive data

 

Monitoring / administration applications

 

 Reports / exports Creating on Excel interface (optional)

 

Management control panel (web browser, can also be used in presentations) (optional)


 Required Tools

workcontrol terminal

(connected to TCP/IP network)


A further advantage of the system, the contains a lot of KPI’s which are computed by the TPC. There is a possibility to show the actual (automatically refreshed) differences between plan / fact.  We provide to the leaders an interactive, easy to use dashboards. The dashboards allow you a continuous and actual overview of your plant in your office.

There are a lot of other possibilities depend on your production:

  • critical values to monitor - to immediate intervention

  • short-and long-term trends, forecasts

  •  detailed Informations in different dimensions (time, manufacturing unit, process)

  •  What-if analysis

The management dashboard developed for leaders:

Figure 4. TPC dashboard for leaders

This dashboard, we developed for production managers

Figure 5. TPC dashboard for production managers


Other options:

  • Plan/ fact comparative option: We compare the current state the production, with the planned and we display it, on a LCD monitor – or on the dashboard.

Figure 6. TPC plan/ fact compare option


  • Production without waste: gear life cycle watching (stop the machine after a gear life cycle to avoid produce a waste)

  • Lower cost of maintenance: you can collect Informations about the maintenances of a machine (maintenance time, changed gear), so you get ready for the future…


Warehouse – stock positioning system

It used to register the current location of the uniquely identified units in the warehouse. With bar code you can identify materials, and semi-finished products, and it does not require placing the materials to a fixed location because on the barcode reader or on a computer you can show the actual place of the products. Beside the exact and immediate position registration, you can obtain full information of the availability stock.

On evaluate the production process it is an important factor the delivery time between the warehouse and production. You can spare time with this system so your process will be more effective.

The data of the movements

  • when

  • who

  • what position

  • which product

  • which quantity

  • direction (in, out)



You can see the availability products default in FIFO sort, but you can define own sort too.

Figure 7. Warehouse – stock positioning system

This module is useable alone, but it can be connected to the production follow up system so it provides complete control over the material flow and production processes.

The content of the program package

 

Communication service program to receive data

 

Monitoring / administration application

 

Reports / exports Creating Excel interface (optional)

 

Management control panel (web browser, can also be used in presentations) (optional)


 Required Tools

 

Multifunction wireless scanner. connected to TCP / IP network


Other possibilities:

  • JIT / records of kan-ban cards: In companies where the logistics has been already in lean-structure (decrease WIP value).

  • Monitor and manage Milkrun system to optimize the deliveries


Production follow up system

The production / usage monitoring system follow the production from the receipt of raw materials throughout the manufacturing process and – working with uniquely identified (bar code) production units - collect data from various movements (when, where, and who moved the article), and record the types of movements too, so supports the analysis to enlarge the efficiency.

Figure 8. Production follow up system

The content of program package

 

Communication service program to receive data

 

Monitoring / administrative applications

 

Reports / exports Creating Excel interface (optional)

 

Management control panel (web browser, can also be used in presentations) (Optional)


 Required Tools

 

Wireless scanner terminal connected to TCP/IP network

or

Wired scanner terminal connected to TCP/IP network

Other possibilities:

  • JIT / records of kan-ban cards: In companies where the logistics has been already in lean-structure (decrease WIP value).

  • Monitor and manage Milkrun system to optimize the deliveries


Working time register

It is used to register the working times under different dimensions (egg, plant, machinery, cost center, location, shift, process). The module can connect to other ERP systems and users log in/check in systems. It can provide data to the HR department (for salary systems).

Figure 8. Working time register

The integration and the level of monitoring can be complete with connect to a log in/check in system.

The content of program package

 

Communication service program to receive data

 

Monitoring / administrative applications

 Complete working time management program


  • working full working hours per month (wage requirements of appropriate) register

  • connection to the log in/check in system (controls)

  • connection to the wage system (export)

 

Reports / exports Creating Excel interface (optional)

 

Management control panel (web browser, can also be used in presentations) (optional)


 Required Tools

 

Wireless scanner terminal connected to TCP/IP network

or

Wired scanner terminal connected to TCP/IP network.


We provide a complete program to manage working times.

  • master data for workers (egg, photos, job hierarchy level, entry, exit date, annual leave)

  • Calendars can be defined for each employee (working days, holidays)

  • Monitor detailed activities (when, how long, where and in what process do you worked, or not worked, holiday, sickness, a certified absences, etc.).

    • Multi dimension working time (egg, process, sub process, cost center).

Other possibilities:

  • access control (depends on hierarchy)

  •  master data, time management interface

  • queries

  • exports (contact wage/salary program / Nexon /)

  • check working time data (compare data with the log in system if possible)

Summary

The TPC System (with the four modules and easy installation and easy to use) is an unique solution for the company’s, who want to optimize the production processes. If your company's use an ERP / SCM / CRM system, contact us to know more about our integration solutions, since the TPC can assist in the effective corporate management. The KPI’s and indicators, as well as their technical background (Excel spreadsheets, information portals / dashboard) can be adapted to your needs. The data visualization tools can be used to inform users in many ways:

    • SQL exports

    • SMS sending (in case of a condition is true)

    • Automatic e-mail reports (errors, KPI’s ...)

    • ON-LINE TV presentation into his production (egg, to show the actual planned qty and produced qty).

One system that continuously keeps under control the production. Checks and provides real-time data on your computer.

 
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