Manufacturing 4.0

How to Increase Production Efficiency?

SISTRADE has the right tool to push your company to Industry 4.0, optimizing, automating, and controlling your production line. One of Sistrade’s key applications is Manufacturing Execution System (MES), which delivers solutions to plan, collect data, supervise, and control the industrial process.

SISTRADE offers solutions allowing to generate appropriate information to quickly support decisions, incrementing productivity, aligned with the foundations of Industry 4.0.

Product Lifecycle Management (PLM)

As a starting point of Manufacturing 4.0 implementation, it is important to define a set of processes related to Product Lifecycle Management. In this regard, SISTRADE offers features which contribute in a significant way to an efficient PLM. It is important to highlight that production management is mainly supported by the management of job orders, which have direct readings of all elements and processes defined by PLM.

Job Order (JO)

A job instruction sent to the shop floor is designated by Job Order and can be issued manually or automatically through registration of a client order or through the MRP (Material Requirements Planning).

Supervisory Control and Data Acquisition (SCADA)

SCADA is web-based software, which retrieves data from operators, machine sensors, PLCs (Programmable logic controllers) and various devices within a plant, even in remote locations. SCADA has the ability to present a 3D plant of all machines, operators, and processes in real time, allowing to reduce unproductive time.

Data Acquisition

The system provides a web-based data collection that enables organizations to manually collect industrial data from industrial consoles, mobile devices or directly from machines and PLCs, applying the concept of "Internet of Things". Sistrade® software allows organizations to automate their production processes, and optimize their production lines and transform into a SMART FACTORY.

Dashboard Continuous Improvement with Lean methodology

Sistrade® brings Continuous Improvement to the future, offering an interactive dashboard used to support the Lean implementation, substituting pen and paper dashboards with a highly dynamic and interactive dashboard.

Andon Board

Sistrade® delivers a digital board displaying status changes of production lines and alerts when events happen.

Overall Equipment Effectiveness (OEE)

Overall Equipment Effectiveness quantifies how well a manufacturing unit performs relative to its designed capacity, during the periods when it is scheduled to run. Sistrade® software delivers OEE supervision and analysis in real time in order to optimize production performance and efficiency, contribution to a company’s continuous improvement.

Production Reports

Managing production requires further analysis through interactive reports, in order to get insightful information to support managers' decisions. Sistrade® Production Management brings Shop Floor Control to another level by providing detailed reports regarding production, employees and resources productivity.

Scheduling

Sistrade® Scheduling offers a solution to organize all tasks and activities in an automated, fully interactive Gantt chart. The software has the ability to allocate machines and resources to its employees, offering drag and drop feature, within the chart, resulting in a fully dynamic system.

Productions record

Sistrade® is prepared to register products manually by the operator through the console, or automatically via PLC, by placing sensors on the machinery.

• Registration of produced quantity in the industrial console
• Registration of produced quantity via industrial automation
• Calculation of production using a function of production time or speed
• Connecting weighing equipment to determine actual weights
• Productions in two measuring units (e.g. meters and kilograms)
• Traceability of the production process

Raw Materials Management

Sistrade® offers a complementary module to manage raw materials. This module consists of the definition of product trees, formulation, manual and automatic consumption, according to incorporation factors.

Quality Control

A company's reputation relies on its products and services quality, which requires a high degree of control to fulfil clients' requirements. Sistrade® ERP offers a wide range of solutions in this department to improve product quality, focusing on detecting non-conformities, calibrating equipment, managing equipment costs. The software is prepared to respond in real time to all challenges, giving the user the possibility to record every information for future historical analysis. Additionally, this module is prepared to trace each equipment and material available, in terms of non-conformities, tests, and inspections.

Industrial Costs

A production process can be very expensive, that is why managing industrial costs is a key activity for every manufacturing company. Summing up direct materials costs, direct labour costs and manufacturing overhead in production gives us the industrial cost of manufacturing. Sistrade® offers a solution to register every cost of materials, including indirect costs in order to calculate cost estimation closest to real.

Asset Management

Asset management requires special attention from every organization, especially the ones, which have critical equipment as crucial investments. Poor asset management can lead to huge financial losses.

Dashboards

Analyse information about returns to the supplier and average delivery time, product consumption, bank account cash flows, work efficiency per employee and other information with Sistrade® Dashboards for different business areas.

Business Intelligence

Sistrade® Business Intelligence is a tool that collects and compiles large amounts of data in order to generate relevant information regarding the companies’ operations. Through this module, companies have a better understanding of the daily operations as well as their environment.
Business Intelligence has a wide application when applied to an organization, as for example, Business, Finances, Sales, Purchases or Production.

Main Features for Production

• Deadline compliance rate, where the satisfaction rate between the agreed delivery date and actual delivery is presented
• Job order costs (actual cost vs estimated vs sales value)
• Setup time rate, where it is possible to view the percentage of setup time over the total production, allowing the user to check the setup time of machines in order to carry out a given production
• Availability ratio: the period of time the machine/section/plant should work vs the time it is working

Watch the solution of Manufacturing: