MES-Technical Information
ASAP-CRS©
Technical Information
Platform Compatibility
ASAP is compatible with Windows XP, and Windows NT. Some modules may be available in Linux in the first half of 2004.
Scheduling
Schedulers assign production to machines in the factory based on available capacity, then the Scheduling module recalculates estimated completion times. We support Repetitive (Build to part number specification), Work-Order (Job shop) and hybrid manufacturing models.
The schedule is shared between the scheduling department and the
shop floor through a publishing mechanism developed by our systems architect.
The scheduler works "off-line" until a satisfactory schedule is produced. The
schedule planner publishes the schedule to the PC's on the shop floor. This
method allows schedulers to analyze different production schedules before
committing to them. This method also provides a stable picture to the
production team - an important consideration in any manufacturing environment.
Scheduling Module Screens
Ease-of-Use Features include:
- Graphical Machine Loading Indicator
- Product to Machine Correlation Tables
- Machine Run-Rate Tables
- Work Center Management
Reporting
Scheduling reports are built into each department's scheduling module.
Scheduling reports include:
- Raw Material Requirements
- Exception Reports
- Schedule Conflict Reports
Sample Operator's Schedule Report
Resource Calendars
Machine availability is tracked in ASAP-CRS' resource calendars.
Holidays, scheduled maintenance, and your production shifts are defined against
machines or work centres to allow the most accurate calculation of your
production schedule.
Machine Calendar
Screen
Synchronous Manufacturing
ASAP-CRS supports synchronous manufacturing, where the schedules of all processes to complete a product order are linked, and the scheduling of downstream processes is adjusted as data is collected from earlier processes. Machines are grouped in "work centres" to support this functionality. Of course these same machine/resources may be scheduled independently to complete other jobs.
Shop Floor Data Collection
ASAP-CRS shop floor data collection brings the simplicity of the Windows interface to the production environment. Factory workers choose the job they are working on from a pick list presented on the shop floor PCs and log production with minimal keyboard input. Data is captured in a transactional format for ease of integration with accounting. ISO 9000 standards are supported by our data collection module.
ASAP - CRS may be integrated with Programmable Logic Controllers (PLCs) on production machinery through standard interfaces such as RS-232 ports or Ethernet network cards. The use of bar-code technology at the data collection stage is also supported.
Ease-of-Use features include
- View Job Pick-List by Job Number, Machine Number, etc...
- Colour-Coded Job Status Indicators
- Real-Time Balance-to-Completion statistics
- Integration with tagging - create tags and production transactions simultaneously
Order Tracking
ASAP-CRS supports the use of dockets, traveller packs, or shop work orders to track orders and work in process (WIP) through the plant.
Downtime Recording
Operator efficiency and machine efficiency can be monitored through the Downtime Recording Module. In addition to collecting raw time statistics for unscheduled downtime, reason codes for each instance are captured. Identification of downtime trends will enable you to deal with underlying problems in machines or processes, and spot training deficiencies.
Downtime Reporting Includes:
- Downtime by Machine
- Downtime by Product
- Downtime by Operator
- Operator/Machine Efficiency Reports
Tagging and Bar Coding
ASAP-CRS supports industry standard printers with Windows drivers. Dot-Matrix, Laser or Thermal Transfer Printers may be used. Bar-coding is supported either through printers' native fonts or through Windows TrueType bar code fonts.
Each production tag is serialized, for easy trackability, or we can work with your serialized bar-coded Traveller Packs.
The ability to classify goods as Reject or Scrap production at the time of tagging is provided, with the classification being printed on the tag. Goods may also be reclassified as a secondary part number if this is required by your grading process.
Tags may be produced for single units of production, containers or
pallets. Formats may be customized to suit your requirements.
Sample Tags - In Process Goods
Sample Tags - Finished Goods
Customizable Tagging
In cases where you have changing tag requirements, ASAP-CRS' Customizable Tag Module may be appropriate. This module allows you to design new tag formats as required. Links to your production data are maintained, both for tag formatting, and transaction capturing purposes, and Bar Coding capability is supported. This is ideal for meeting customers' specific label requirements, and for supporting EDI labelling formats.
Quality Control
Quality Control data collection can be included in your ASAP-CRS installation. Supporting multiple test result entries per production batch, ASAP-CRS QC module is suitable for plants producing continuous products, such as plastics or wire. ASAP-CRS QC is fully integrated with Tagging and Scheduling.
Alternatively, third-party QC products may be integrated with ASAP-CRS.
Integration
The scheduling and data collection modules are integrated with each other, providing a real-time feedback loop between the scheduling department and the shop floor.
ASAP-CRS may be integrated with your manufacturing systems as well. Batch transfers and direct database access (through Borland's BDE and ODBC drivers) are supported. Oracle, Informix, Sybase and other databases are supported through LAN connectivity (Novell, UNIX, Windows NT, TCP/IP).
ASAP-CRS has been successfully integrated with packages such as Syspro's Impact Award and QAD Inc.'s MFG Pro. Integration with Lilly Software's Visual Manufacturing is under development.
Production Reporting System
Production reports are accessible through the Reporting System, which may be installed on a system independently of other modules of the ASAP - CRS.
Included in the Production Reporting System:
- Production by Product
- Production by Machine
- Production by Work Order
"Observer" Systems
Windows PCs on the same network may be set up with a read-only version of the production schedule, allowing the user to monitor jobs on the shop floor. This is often used to coordinate the flow of materials through the plant, and to facilitate raw materials planning.
History
Production history is maintained through a log of all tags printed by the data collection PC's, and their associated transactions.
ASAP-CRS uses the popular Paradox file format, so ad-hoc querying, analysis and reporting of your data may be performed using tools such as Borland's ReportSmith or Paradox for Windows.
Fault Tolerance
ASAP-CRS is a built on the Distributed Data Base Model which gives you unparalleled fault tolerance. In the case of a network system failure, the data collection system continues to function. When the network resumes normal operation, the data is uploaded to the central server, and all data is synchronized among all the remote systems in the network. ASAP-CRS also incudes our own proprietary technology for rebuilding and restoring any files that are damaged during machine or power failures.
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