- ERP/MRP Integration
- Family Tool Tracking
- Labor Tracking
- KanBan Scheduling
- Preventive Maintenance Package Integration
- Process Journals/Historians
- SQC Package Integration
Snapshot®, Portrait® and Panorama® integrate with the following ERP/MRP packages:
- JD Edwards
Family Tool Tracking runs and tracks multiple parts on the same machine simultaneously. There are considerable savings to be realized by running all the parts of one product with one tool but, in the real world, family tools are very difficult to run efficiently. The machine parameters that work well for one cavity, produces rejects in another. Rejects in one cavity produce uneven product inventories and hard-to-track scrap loss. Accurate materials forecasting is difficult due to the different part weights for individual cavities. If you do not get complete sets from every cycle, you may not have the required quantity from the less productive cavity before shut down.
Family Tool Tracking deals with these issues by treating the individual component part as “children” in the multiple part tool. Each “child” is assigned a unique part identifier when the original product standard or “parent” is created so each piece from a multiple part tool can be tracked independently as a separate job.
- Runs and tracks multiple parts on the same machine simultaneously
- Forecasts material requirements and completion dates by component part
- Tracks scrap factors by individual components
- Maintains accurate inventory counts
- Provides traceability for quality documentation
- Creates packaging and labeling instructions per individual part number
KanBan is a Japanese scheduling system developed by Toyota in the 1940s that ensures that workers have what they need, where they need it, and when they need it — without the liability of maintaining expensive and wasteful inventory levels. Kanban is now an integral component of lean and just-in-time production programs.
KanBan utilizes cards as a visual aid to trigger action. For instance, each bin of parts in a production process has a KanBan card. The card documents the number, type of part, vendor and other information needed to order or produce the parts. Six bins are in inventory at the start of the work cycle. A card is pulled as each bin is put into production. When the operator has four cards, he knows it is time to order six more bins. He uses the SYSCON-PlantStar computer interface to enter the necessary information that will generate the order. If the cards are barcoded, he scans each card into the barcode station and the request for six more bins is automatically entered in the system.
SYSCON-PlantStar can also implement an electronic Kanban (e-Kanban) system that will eliminate problems associated with using Kanban cards such manual entry errors and lost cards. PlantStar’s e-Kanban offerings include Radio Frequency Identification (RFID) input for scheduling Kanban quantities. Data gathered from PlantStar’s e-Kanban scheduling module will further help manufacturers track lead and replenishment times for materials.
Labor Tracking identifies labor costs and maximizes labor productivity. Labor Tracking automatically collects, forecasts, and reports the labor hours with associated costs by machine, job, shift, or employee. With user-defined labor categories for specific jobs or applications, Labor Tracking provides detailed picture of man-hours for operators, electricians, material handlers, maintenance workers, packers, tenders…any plant floor personnel whose activities are focused at a machine or work center.
- Forecasts labor requirements
- Develops accurate direct and indirect labor costs
- Analyzes labor performance for precise job costing
- Imports/exports utilities to minimize data entry
- Exports labor statistics into third-party software for extended analysis and forecasting
Snapshot®, Portrait® and Panorama® integrate with the following Preventative Maintenance packages:
- CWorks Systems
Process Journal allows users to enter notes for Cause and Effect documentation. After logging in, the user can create notes for Downtime, Scrap, Process Variables, Machine Maintenance and more. The notes may be linked so others can view the progression of activity. A typical scenario is when an operator sees a problem with a part—he notes the problem and takes corrective action by calling Quality Control (QC) to the press. QC reviews the problem and notes that the problem is machine related and contacts Maintenance. Maintenance fixes the machine and documents the action taken to correct the problem.
Snapshot®, Portrait® and Panorama® integrate with the following SQC packages:
- Infinity QS
- Hertzler – GainSeeker