The experience gained by IPESOFT in recent years by implementing support systems for manufacturing management in the power sector and industry show that the biggest benefit for the client is a relatively comprehensive solution. A comprehensive solution is the one covering the bigger part – preferably the entirety – of available sources of manufacturing information. Doing so, the solution application needs not to cover all the areas expected in a MES solution. In large plants this can include thousands data that need to be collected, evaluated, archived and accessed for further processing. Further processing means provision of information about the current state of manufacture, calculations of production balance and energy balance, statistical quality assessment, key performance indicator (KPI) calculations, preparation of manufacturing schedules, presentation of reports and notices, as well as calculations of predictions for maintenance needs, preparation for work, communication with ERP system and similar. This is quite a wide range of activities taking place in real time (during a production shift).

Implementing a MES solution is not a trivial issue. It requires some insight and experience to design a solution, a reliable and powerful software platform for real-time applications, erudite implementation team, close cooperation between the customer and solution provider or an established methodology. In addition, such implementation is time-demanding, although the rate of return of the investment is usually very high. IPESOFT offers a support in every stage of solution commissioning for its clients and partners.

The methodology we use in the preparatory stage has been verified and resulted in a successful implementation of big and complex solutions. The first step is to work out a feasibility study to map the current situation, identify problem points and to propose a solution according to client's requirements. It contains also recommendations exceeding the momentary needs of the client, drafting a concept of the target status that can be much broader than the current assignment. At the very beginning, this approach precludes problems with possible (and very likely) expansion of the system in the future. The study includes a cost and work load estimate, schedule and particular stages of the solution allowing its progressive implementation according to client’s priorities and their technical and economic possibilities. A detailed specification of the solution based on the study and client's decision which part will be implemented as the first, is a document worked out jointly by our engineers and client’s representatives. A bilateral approval of this document ensures equal expectations on part of both the client and the provider to minimise disappointment that might happen under different circumstances. It guarantees that the client will get what they expect to get and still it keeps the door open to further development of the solution according to its own growth, while the initial investment into the solution remains protected and continues to appreciate.

Implementation of a properly scaled solution means that several technical requirements need to be satisfied. D2000® is real-time module-structured technology and its application in diametrically opposite applications proves that it is very suitable for MES solutions. It is also important to have an open and flexible technological infrastructure. This means, for example, a possibility to include other computers into the network or to connect and communicate with existing sources of data. The feasibility study usually identifies possible limiting points and recommends a relevant adjustment for such limitations.

An obvious requirements is application modularity of MES functionalities. Generally applicable modules repeated in every application (Technological Information module, Energy Balance module, Manufacture Monitoring, Manufacture Balance, Manufacture Short-Term Scheduling, Operative Maintenance Support…) that minimise implementation demands are readily available in our MES solutions. Considering differences of various manufacturing plants, the modules are configurable and refined according to specific requirements of relevant customers. In addition, we offer industry-specific application modules, such as modules for glass industry, paper industry or power sector, that reduce both implementation and servicing costs of the solution.

Our capability to provide big comprehensive solutions allows us to see beyond the horizon of your current needs and to offer a system vision that will not just copy the growth of your enterprise, but rather grant it becoming a determining tool ensuring such growth and a successful management of a dynamically developing company. Innovative production processes of the future, such as adaptive manufacturing units, knowledge-based manufacture, network enterprises etc., are implicitly based on existence of a smart manufacturing system functioning as their information centre.

>> Links Back - Main Page / Manufacturing Information Systems