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Exploring MES Intelligence

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Savvy business owners are always looking for ways to improve your business intelligence (BI). Your BI gathers data in a way that helps you make informed decisions about the future of your company. MES Intelligence is a great solution for boosting your business’s efficiency.

In this blog post, we’re going to explore the ways MES can help with that. We’ll discuss what an MES is and how it gathers data. We’ll also look at different ways this software can improve business intelligence and help you make better decisions for your company.

What is an MES System?

A Manufacturing Execution System (MES) is a software application that helps manufacturers track and manage the production process. These systems gather data from various sources, including sensors, machines, and humans. This data is then used to improve manufacturing processes and make better decisions about production.

MES intelligence can help manufacturers understand how their operations are currently functioning and which areas can be improved by implementing more efficient workflows.

Ways MES Systems Can Gather Data

MES software can gather data in a variety of ways. It can collect and record data in real time on the production line. Changes in inventory levels are automatically triggered by the manufacturing process’s development. Then the inventory is adjusted instantly when a technician determines that a specific activity is finished.

These solutions can also keep track of data such as the time it takes to complete each step, at each station, and by each employee. It may even monitor statistics on workplace accidents happening in the manufacturing facility.

How This Intelligence Can Improve Businesses

MES systems can improve business intelligence in a number of ways. One way is by providing data that can be used to improve manufacturing processes. For example, if the data shows that a certain machine is consistently running at a higher temperature, this system can be used to make changes to the process that will improve the quality of the product.

These systems can also be used to make better decisions about production. For example, if data shows that a certain product is not selling well, the MES can be used to make decisions about how to change the production process in order to improve sales.

This software provides powerful data analysis capabilities. These extract insights from data on a regular basis, and they can be utilized to improve processes. MES solutions can be connected to the cloud and may easily send data for analysis using any other technology. This software is a versatile data analysis tool for manufacturers because of these capabilities.

Want More Information About MES Intelligence?

MES systems are the one-stop shop for data needs for process improvement in any manufacturing plant. This solution allows you to automate processes and improve efficiency while reducing cost. The structure of an MES is intended to support manufacturing data usage scenarios. It makes data processing easier, faster, and more efficient.

If you’re interested in learning more about how MES systems can improve business intelligence, reach out to the professionals at VersaCall. We can help you find the right solution for your company. Contact us today to learn more!

MES vs. ERP Systems: Differences and Similarities

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What’s the difference between MES and ERP systems? Many business owners and managers are unsure of the differences between these two types of systems, and even more uncertain of which system they need for their business. In this blog post, we will break down the differences and similarities between MES and ERP systems, to help you decide which system is best for your business.

What is an MES System?

MES systems stand for Manufacturing Execution Systems. These systems are used to track and monitor the production process in manufacturing environments. MES systems can be used to track things like raw materials, production progress, and finished products.

An MES is used to gain insight into manufacturing operations in order to analyze what may be improved and how costs can be reduced and production efficiency can be increased. An MES can collect real-time data, enable production analysis, and enforce process requirements.

Benefits of an MES system

Some of the benefits of an MES system include the following:

  • Reduction in operation cost
  • Improvement in productivity
  • Real-time visibility

What is an ERP System?

An Enterprise Resource Planning (ERS) system is used to manage operational activities such as plant scheduling, order processing, inventory management, and customer service. Manufacturing ERP software, as opposed to MES software, is designed to increase company performance by providing reports on business operations and suggesting where procedures may be streamlined.

An ERP can oversee business operations, perform scheduling, integrate business processes with manufacturing processes, and track materials.

Benefits of an ERP System

Some of the benefits of an ERP system include the following:

  • Better inventory control
  • Better customer experience
  • Mitigation of risk

What are the Differences Between MES and ERP?

Now that we know a little bit about each system, let’s dive into the differences between the two. Some of the differences between MES and ERP include the following:

  1. How Data is Kept and Delivered: MES systems are designed to keep track of data in real-time. ERP systems, on the other hand, are not built to handle real-time data. The data from an ERP system is typically batch processed and delivered at set intervals.
  2. Functionality: ERP and MES systems fulfill different purposes in the manufacturing industry. MES was designed to handle the day-to-day activities of your manufacturing process and operations in real-time, which is where it differs from an ERP system. An ERP system focuses on scheduling and quantitative analysis.
  3. System Integration: ERP systems are not always easy to integrate with other software. MES systems, on the other hand, are designed to be easily integrated into other software.

What are the Similarities Between MES and ERP?

Now that we know some of the key differences between these two types of systems, let’s take a look at some of the similarities. Some of the similarities between MES and ERP systems include the following:

  1. Data Management: Both MES and ERP systems are designed to manage data. This data can include things like customer information, product information, supplier information, etc.
  2. Process Automation: Both MES and ERP systems can automate processes. This automation can help to improve efficiency and productivity.
  3. System Administration: Both MES and ERP systems require system administrators. These administrators are responsible for managing the system and ensuring that it is updated and running smoothly.

Need an MES or ERP System?

Whether you are considering an MES or ERP system, or both, the professionals at VersaCall can help. We have a team of experts who can help you to select the right system for your needs and budget. Contact us today to learn more!

 

Core Functions of a Manufacturing Execution System (MES)

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Manufacturing Execution Systems (MES) are software platforms that help manufacturers optimize and monitor production processes. These systems collect data from shop-floor machines and sensors, schedule resources and tasks, manage workflows, and analyze performance. In this blog post, we will discuss the core functions of an MES.

Core Functions of an MES System

An MES is the comprehensive system that controls all the activities occurring on the shop floor. It begins with all the various orders from customers, the MRP system, the master schedule, and other planning sources; and then builds the products in the most effective, low cost, expedient, and high-quality way possible.

Here is a more thorough explanation of each core function:

Data collection and acquisition: MES systems collect data from shop-floor machines and sensors. This data is then used to schedule resources and tasks, manage workflows, and analyze performance.

Scheduling: MES systems schedule production tasks based on the data collected from shop-floor machines and sensors. The goal of scheduling is to optimize production processes through specific scheduling so that they are more efficient.

Staff and resource management: An MES helps you manage production staff and resources. The goal of this function is to ensure that production processes are carried out in a safe, efficient, and effective manner.

Process management: They also aid in managing production processes. The goal of this function is to optimize production processes so that they are efficient and effective.

Maintenance management: This system will help manufacturers more easily and accurately plan preventative machine maintenance to reduce downtime and production interruptions.

Performance analysis: MES systems analyze performance data to identify areas of improvement. The goal of this function is to improve the efficiency and effectiveness of production processes.

Document management: These systems manage production documents. The goal of this function is to ensure that production documents are accurate and up-to-date.

Quality management: An MES manages the quality of your produced units—including quality deviations and exceptions. MES allows you to open tickets and track resolutions to quality issues.This function can be integrated directly into the software or can use external software.

Labor management: With these systems, you can easily manage your people, products, and/or operations and track any skills or authorizations they require. This ensures that you always have the right people in place at each step of the production process.

These functions mentioned above are just  some of the capabilities that an MES can provide. If you would like to learn more about how an MES system can specifically benefit your manufacturing business, professionals at VersaCall can help.

Benefits

There are many benefits of an MES system. Some of these benefits include the following:

  • Reduces manufacturing cycle time
  • Reduces or eliminates data entry time
  • Reduces work-in-process
  • More reliable and precise sequence planning
  • Improves product quality
  • Reduces or eliminates paperwork between shifts
  • Reduces lead times
  • Improves customer service
  • Reduces setup costs, wait times
  • Eliminates lost paperwork
  • Empowers plant operations people
  • Improves the planning process

 

An MES automation system can deliver significant improvements in bottom line profitability, on time delivery, and better quality products.

Learn More About MES

If you would like to learn more about Manufacturing Execution Systems and how they can benefit your manufacturing business, please reach out to our professionals at VersaCall. We would be happy to answer any of your questions.

 

6 Examples of Andons and Their Uses

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Andons and their uses

In the manufacturing world, an Andon is a signal device that alerts operators or management to a problem. There are many different types of Andons, but all share the same purpose: to notify operators and first responders of a problem so they can take corrective action.

Here is an explanation of Andons, as well as six real-world examples of Andons and their uses.

What Is an Andon?

Andon systems are a type of visual management system. They consist of a series of lights or signals that allow operators to communicate problems to management. The name Andon is derived from the Japanese term “andon,” which means “lamp” or “light.”

The name “Andon” comes from the original Andon systems, which were llight-up boards that glowed when an andon cord was activated. Modern Andon systems employ the use of tower lights, screens, and additional methods of communications, to notify management and personnel of issues.

Examples of Andons

Here are six real-world examples of andons being used in different industries:

1. Toyota

Toyota is known for its well-run manufacturing plants. The Toyota Production System (TPS) uses a number of visual management tools, including andons.

The Andon system consists of every Toyota automobile having a portable indicator light on the production line, following it down the line. That indicator light has blue, green, and red lights. The light turns from blue to green when a mechanic tightens a bolt on a vehicle, and the automobile continues down the line.

However, if one of the bolts on a production line is excessively tightened or left untightened, the indicator light flashes red and the Andon board turns orange on that area of the manufacturing line. If the bolt is not addressed promptly, production will be halted and the team must congregate to quickly address the problem at that part of the manufacturing line.

2. Amazon

Andon systems help Amazon maintain their high standards of good packaging, quality service, and speedy deliveries. The Andon alerts at Amazon indicate a variety of issues on the production floor in real-time, meaning time isn’t wasted on fixing issues such as defects in inventory, reported product updates, etc.

Andon systems give workers and supervisors a chance to reduce wasted time and monitor each other’s progress and performance. Amazon’s massive workloads of packing and shipping products requires as little waste as possible, and Andons help accomplish this.

3. Honeywell Andons

One of Honeywell‘s locations consisted of 4 separate factory operations with one common support group. VersaCall helped Honeywell to implement an Andon system which reduced line downtime for the 4 separate factory operations.

The one support group had previous difficulty in identifying and fixing problems quickly. The Andon system helped the support group by providing them with immediate communication of where line stoppage issues were across the 4 separate factory operations.

4. 3M

At the 3M Tape Manufacturing Plant located in Minnesota, the facility was experiencing a significant loss of production time due to the response time of support personnel to unanticipated production disruptions. This plant implemented VersaCall’s VT3000, an Andon system which included 4 button calls that were within reach of every operator.

The press of a button sends communication immediately to a specific person or group who will need to address problems in that specific area. The Andon system helped provide an immediate response to issues.

5. Caterpillar Inc. Andons

Caterpillar Inc. has implemented the Caterpillar Production System to continue to improve their production processes by determining an effective way to communicate problems and issues from the assembly line on the production floor.

The Andon solution used was VersaCall’s 4 Button Wireless Call Station with stack lights at each work station on the production line with the ability to send communications to any location on the entire site. There is also display software for displaying the status of the entire production line as well as the status of each of individual work zones. 

Helping employees and management see the production status by individual production line and work zones was key in reducing downtime and response time.

6. Hamilton Sundstrand Andons

One operation of Hamilton Sundstrand consists of many assembly lines and groups, yet only one support group. Hamilton Sundstrand opted for an andon system that would help them identify the root cause of problems when they arise. 

VersaCall’s BSC Modules at each of the assembly stations provided for the immediate communication of multiple support requests. The modules captured the time and reason associated with each support request to provide the root cause of time loss on the floor.

Looking To Implement Andon Systems?

Each of these types of Andons can help manufacturers ensure that their operators and management are alerted to any potential problems so they can take corrective action.

If you’re looking for a way to improve your manufacturing process, consider using an Andon system. Contact VersaCall today to learn more about our Andon systems and how they can benefit your business.

How Andons Can Reduce Costly Manufacturing Downtime

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Andons Can Reduce Costly Manufacturing Downtime

In the manufacturing world, downtime is costly. Every minute a machine is not producing a product can mean lost revenue. In an effort to minimize this loss, many manufacturers have turned to Andons. 

Manufacturers in many different industries have found that Andon systems work efficiently in reducing manufacturing downtime. Here’s some more information about how Andons can help reduce costly manufacturing downtime.

What is Manufacturing Downtime?

Manufacturing downtime is the amount of time a machine or process is not running. This can be caused by a number of factors, such as equipment failure, material shortages, or operator error.

Downtime can have a significant impact on a company’s bottom line. In fact, it is often one of the most expensive aspects of manufacturing.

What are Andon Systems?

Andon systems are a type of visual management system. They consist of a series of lights or signals that allow operators to communicate problems to management.

The name Andon is derived from the Japanese term “andon,” which means “lamp” or “light.” The name “Andon” comes from the original Andon systems, which included light-up boards that glowed a specific color indicating any issue affecting production. The Andons cord was a physical action that workers could take to indicate that there was an issue in production, and they could also use it to stop production entirely if necessary.

Modern Andon systems employ the use of tower lights, screens, and additional methods of communications. An example of the meaning of visual signals on the floor is green for normal operations, yellow indicating that changes are called for, and red as an indicator that production has stopped.

While Andons can be used in any manufacturing setting, they are most commonly found in assembly plants and on production lines.

There are several benefits of using Andon systems, as they can

  • Identify and address problems quickly
  • Improve communication between operators and management
  • Reduce and track manufacturing downtime
  • Analyze downtime events to continuously improve 

How Can Andon Systems Reduce Manufacturing Downtime?

Andon systems are an effective way to minimize the cost of manufacturing downtime. They provide a way for operators to signal issues to management quickly and effectively. By identifying and addressing problems as they occur, companies can minimize the amount of downtime their machines experience. 

In addition, Andon systems can help improve communication between operators and management. This can help ensure that problems are addressed promptly and that everyone is aware of the status of the production line. When the problems are addressed promptly, the manufacturing downtime can be greatly reduced.

Want to Reduce Manufacturing Downtime?

If you’re looking for a way to reduce the amount of manufacturing downtime your company experiences, consider installing an Andon system. Andon systems provide the perfect way for operators to signal problems to management quickly and effectively. This can help identify and address problems quickly, minimizing the amount of downtime your machines experience.

For more information about Andon systems and how they can help reduce downtime, contact VersaCall today.

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