Merz s.r.o.

The project was implemented at two stages. The first stage included the data collection from 10 dismantling and renovation workplaces (4 months duration) and the second stage included the implementation of data collection from 12 assembly line workplaces (6 months duration). The manual production corresponds to the data collection from the production lines. The production information is collected by means of the entering panel (industrial computer with a touch screen) and chip cards scanner. The other data sources are the data outputs from the testing machines.

Goals of the project

• Provide the sequencing of the production orders in time.
  
• Monitor the process and fulfiment of the orders.
  
• Provide a review of available components in the storage area.
  
• Administration of the inspection protocols.
  
• Provide and control the maintenance for the specified devices (calibration)
  
• Monitoring the events on the lines (particularly the idle time)Zajistit řazení výrobních zakázek v čase.

Benefits of the implemented solutions

• Analyse the causes of defaults and time demand factor of the tests
  
  • Rewriting the production records to the computer is not required => time saving of the quality employee by approx 30min/day
    
  • Reduction of defective work from 3.5% to 2% => increasing the production by 4 pieces/day
    
• Monitoring the idle time => reducing the idle time resulted in increased production of 3 pieces/day
  
• Tool for improved planning
  
  • Optimizing the line utilization
    
  • Implementing the IAM production whilst maintaining the existing number of planners
    
• Defective pieces register
  
  • Reduction of time for preparing documents related to defective work => time saving of the quality employee by approx 30min/day
    
  • Identification of defective pieces from the production information system (Merz) to the warehouse system (Losy) - time saving of thequality employee by approx 60min/day
• Availability of actual electronic documentation on the line
  
  • Saving time for readjustment - saving non-productive time of the respective employee by approx 15 min/day
    
• Electronic planning of maintenance
  
  • Providing accurate register of maintenance work and calibration => time saving of the quality technician by approx 60min/day
    
• Indication of non-standard production procedures => reduction of potential defect occurrence
  
• Electronic data download from the reporting system (MOPS system)
  
  • Reduction of time for preparing documents from the foremen and other respective employee => time saving of the foreman and the respective employee by approx 60min/day

Basic function of the information system

• Implementing the production orders in time planning
• Monitoring the job order process
• Synchronising with the component storage area
• Identification and administration of the production and material defective products
• Monitoring and classification of idle time
• Accessibility of the production documentation for the production employees
• Entering and viewing the inspection protocols
• Integration of the oil test evaluation in unified collection application.

Technical solution scheme

Applied software / hardware elements

• Access to the applications is implemented by means of internet browser from any computer connected to the Intranet network.
  
• The data collection from the control systems by means of OPC communication protocol
  
• The main applied database is MS SQL
  
• Implemented automatic synchronization with the existing ERP-system (data regarding the production orders, attendance system)
  
• PLC Koyo
  
• Fitting the standard OPC servers:
  
  • OPC Server Koyo