How do you use production software intelligently for the digital factory?

The digital factory and smart production management for Factory 4.0

Digital factory

The call to optimize production processes is growing. The ability to adapt to meet the demands of your customers determines the degree of success for a producer.

In addition to customer demands such as quality, delivery time and price, your production must comply with regulations and standards and you want to work on sustainability. This can be done, for example, by using more environmentally friendly raw materials, minimizing your waste or making your production process more energy efficient. At the same time, you want to innovate to develop new products and maintain the flexibility to adapt existing products.

These goals together form a considerable challenge for production companies. One of the solutions that can help is to digitize the process. By replacing paper on the shop floor with an online environment, real-time insight is created that helps you shorten throughput times, reduce quality loss and increase delivery reliability.

Digital-factory-and-smart-production-management

Perhaps you are familiar with the terms 'digital factory' or 'factory 4.0'. They represent a mature production process in which the exchange of information between different production components and physical locations is automated. In addition, a modern organization makes decisions based on generated data to continuously optimize the production process.

Organizations are looking for suitable solutions to digitize their processes. Due to the diversity of production processes and their management, the search often ends in a relatively expensive customized solution.

MyPlantFloor demonstrates that there is another way. This is a modular system that allows you to configure an affordable total solution in a relatively short time, so that you can achieve your goals with relatively limited resources.

On this page you will discover what the digital factory and smarter production management entail. We will also show you how an existing, fully configurable software package makes it possible to digitally control your production.

What is the digital factory?

Various concepts are synonymous with the digital factory. In addition to factory 4.0 and smart production management, we also come across English terms such as 'smart factory', 'smart industry' and 'industry 4.0'.

A factory 4.0 works without paper and from a single dashboard (one digital system) to securely connect the existing technologies within the entire production process. The data exchange between the various business software and the business and the link with associated improvement methods (including Lean, Six Sigma, TPM and Kaizen) is fully automated. The production machines, the management systems, all departments and any customers and suppliers are all digitally connected.

The digital production process is designed to generate valuable data. Not only to monitor quantity and quality, but also to make informed business decisions and thus optimize the production process.

Outline of smart industry production process

In a digitized production process, operators no longer work from paper and different systems, but all tasks are carried out from user-friendly screens. All connections between systems and tasks are secure.

Planning is done at a central location, which allows for efficient logistics, production scheduling, quality control and maintenance. Information about available raw materials, semi-finished products, incoming orders and orders already produced is completely transparent.

Relevant data from all phases of production are recorded for further processing, checks and evaluation. This includes quality checks and audits, information for labels, stocks of raw materials and packaging and energy consumption. In addition, real-time and stored data provide insights for adjustments and improvements. In this way, digitization streamlines the execution of various tasks and prevents downtime.

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What does smart production management add to industry 4.0?

Humans remain crucially important in a digital factory. We are still a long way from the point where computers and robots offer the ideal solution and completely take over the production process. It is not the machines or digitization, but the people behind them who can streamline and optimize processes.

Sure, we can read data from anywhere. However, what matters is what you do with that data. Research shows that when you make production data available throughout the organization, all departments can realize OEE improvements, from production to maintenance and from logistics to quality.

Working smart means sharing experiences from the shop floor with departments such as logistics, technical services, sales and management. But also the other way around. Maintenance is wrongly seen as a cost item. With an alternative mindset, maintenance ensures a higher utilization rate, better performance and a longer lifespan of the operating assets. And thus continuity for your production process.

By giving people more responsibility for the processes within an organization, they feel more ownership. That is where OEE begins. Smart production management means that people make the right decisions on time.

What are the benefits of the transition to smart industry?

Smart industry

Common statements within the manufacturing industry are: “If you digitize a bad analog process, you get a digitized bad process.” and “If you don't collect data in your factory now, you're doomed.”

Smart industry does not only refer to the digitization of data exchange between existing systems within the production process and methods for production improvement, but also to what is needed or what is possible for more efficient and effective business operations. We distinguish the following advantages.

Shorter lead times and greater flexibility
Company data for employees and machines is directly accessible. This makes efficient changeover easier, enabling small-scale production. Your organization can deliver faster and thus respond more flexibly to specific customer requirements. There are known cases in which the turnaround time could be reduced by up to 50% with an average cost reduction of 15%.
Combine mass production with customization
Smart factories can combine mass production with customization, enabling companies to make personalized products without extra costs or production time. The major (price) benefits for customers with specific requirements will give you a significant competitive advantage.
Working more efficiently
When all data is digitally available on a single dashboard on the work floor, employees no longer have to waste time organizing paperwork and searching for crucial data. Data entry is sufficient in one central system.
Better maintenance planning and less downtime
Smart factories are better able to predict maintenance needs based on data from machines and sensors. This prevents unexpected downtime and extends the lifespan of equipment.
Integration of the production chain
With an integrated supply chain, smart factories can quickly adapt to fluctuations or changes in raw materials and supplies. This makes your production system much more flexible and resilient, allowing you to respond better to the market.

More sustainable production and lower costs
Being able to plan production cycles more efficiently, schedule maintenance more tightly, reduce waste of raw materials and lower energy consumption are all achievable goals within the digital factory. This helps to reduce costs and your ecological footprint.
Increased employee engagement
Modern technologies attract young, talented employees. Younger generations have grown up with advanced digital systems and expect to be able to work with them in the workplace. Organizations that embrace technology are seen as more attractive employers.
Reliable deliveries
Integrating inventory management, planning and supply chains with digital systems reduces the chance of shortages and delays. Faster turnaround times lead to higher delivery reliability.
Quality improvement
Digitization leads to fewer errors. Instructions are always up-to-date and available everywhere, which prevents misunderstandings and ensures consistent output. Comparing online measurements with the standard, in particular, makes any defects visible more quickly, preventing unnecessary loss of production due to downtime.
Better customer satisfaction and more profit
A digital production system, smart production management, committed employees and continuous optimization enable you to produce in an increasingly careful and customer-oriented manner. The improved processes allow you to communicate more accurate delivery times and deliver products at competitive prices. You can also share automatic updates on the status and specifications of orders. , are highly appreciated by customers, which leads to a better customer experience.

Configurable-production-software-MES-CMMS-EMS-WMS-QC — Configurable production software MES-CMMS-EMS-WMS-QC

Our developers have developed a configurable solution that can be deployed quickly. Each component uses a single central database and can be used autonomously or in combination with one or more other components. This makes the MyPlantFloor solution highly scalable, effective (tailored to your factory) and therefore affordable.

We distinguish the following components and modules:

Manufacturing control

MES

The Manufacturing Control (MES) component is closest to the production process and forms the basis of MyPlantFor. Imported orders from ERP become visible on the web UI (operator dashboard) for the designated production line. The operator selects and starts the correct order based on the planning. During production, you gain real-time insight into all the details of the production line's performance, displayed in an Overall Equipment Effectiveness (OEE) percentage with extensive specifications. This essential information enables you to respond proactively to events and thus implement improvements on a daily basis.

Optimization and efficiency improvement are the key words that open the door to “doing more with the same resources”.

You gain insight into all phases of the production process, from inventory management to loss registration.
The software exchanges accurate, relevant information securely via the secure link with ERP and the machines.
Production management, operators and machines are connected to each other in real time via a secure network.

Additional modules

We also offer various additional modules to further improve the OEE.

Automatic registration of downtime
Reduction of changeover time
Graphical planning
Label printing
Skill matrix

More information about MES software for the digital factory can be found here.

Would you prefer to ask your question about the additional modules in person? Feel free to contact us.

Quality control

The quality control department handles the processing of online and offline quality tests. Quality control is crucial in every production process, including guaranteeing consistency, customer satisfaction and efficiency. Important reasons to include quality control in every production process are:

1) Consistent product quality: Quality control ensures that each product meets the set specifications and standards. This minimizes variations, allowing customers to experience products in a consistent manner.

2) Cost savings: Identifying and correcting defects early reduces waste of raw materials, time and resources. This also prevents expensive recalls or legal costs.

3) Improved efficiency: A good quality control system identifies inefficiencies in the production process. This makes it possible to optimize processes and reduces downtime or rework.

4) Regulatory compliance: Many industries have strict quality and safety requirements. Quality control helps to ensure that products meet legal standards, which prevents fines and reputational damage.

5) Competitive advantage: Companies with a good reputation for quality stand out from their competitors. This can lead to better market share growth and brand loyalty.

6) Fewer production errors: Identifying errors during the production process, instead of after completion, prevents defective products from entering the market. This improves the overall reliability of the products and the brand.

7) Improvement of internal processes: Feedback from quality control can be used to address weaknesses in the production process and to make continuous improvements. This leads to higher productivity and better results.

8) Higher customer satisfaction: Consistent quality leads to satisfied customers. When products (continue to) meet expectations, a company builds trust, which can lead to repeat purchases and positive word-of-mouth advertising.

More information about MyPlantFloor Quality control can be found here.

Maintenance management

CMMS

Maintenance management is very important in a production environment because it contributes directly to the reliability, efficiency and sustainability of machines and processes.

1) Maximizing uptime: Good maintenance management minimizes unplanned downtime. This is crucial to keep production processes running smoothly and to guarantee productivity.

2) Cost control: Preventive maintenance prevents expensive emergency repairs and extends the lifespan of machinery. This saves costs in the long term and optimizes the use of resources.

3) Increased safety: Regular maintenance identifies and eliminates potential hazards, guaranteeing a safe working environment for employees.

4) Improved product quality: Well-maintained equipment functions consistently and with precision. This leads to higher-quality products and fewer rejects or rework.

5) Greater efficiency: Maintenance management ensures that machines and resources perform optimally, minimizing the waste of energy and materials.

6) Predictable production planning: With advanced techniques such as condition-based maintenance, maintenance needs can be predicted, which helps to improve production planning.

7) Regulatory compliance: Legal requirements for machine safety and operational standards apply in many industries. Maintenance management helps companies to meet these requirements.

8) Longer equipment lifespan: Proper maintenance ensures that machines last longer, which means that capital investments yield a better return.

9) Competitive advantage: Companies with more efficient and reliable production processes can deliver faster and more cost-effectively, which gives them a competitive advantage.

MyPlantFloor - CMMS

The maintenance management component consists of a CMMS module (Computerized Maintenance Management System) with the following main tasks:

Limiting unplanned maintenance due to technical malfunctions
Efficiently planning required maintenance, increasing the factory's productivity and reducing maintenance costs.

You can use MyPlantFloor - CMMS as a stand-alone system, but we usually see it used in combination with Manufacturing Control. A modern maintenance control system like MyPlantFloor offers advantages such as:

The maintenance department has real-time and historical insight into the condition of the production lines.
Operators can create work orders directly from the operator dashboard.
Operators with sufficient knowledge can take over certain maintenance tasks from the maintenance service (autonomous maintenance).
Multiple lines, multiple controllers, multiple branches and multiple languages can be integrated.

You can find more information about CMMS software for smart industry here.

Energiemonitoring

EMS

Precise energy management in a production process helps to reduce operational costs and increase overall efficiency. It also contributes to sustainability goals.

Digitale-fabriek-Energy-monitoring-Energy-control

1) Cost savings: By optimizing energy consumption and reducing waste, companies can realize significant cost savings, especially in energy-intensive production processes.

2) Improved efficiency: Effective energy management ensures that machines and processes operate more energy-efficiently. This increases overall productivity without consuming additional resources.

3) Reduced environmental impact: Smart energy management allows a company to reduce its ecological footprint. Consider, for example, the use of renewable energy sources, the reduction of emissions and a lower dependence on fossil fuels.

4) Regulatory compliance: Many countries and regions have strict energy and environmental regulations. Good energy management helps companies meet these requirements and avoid fines or damage to their reputation.

5) Competitive advantage: An efficient energy management program can reduce operating costs, which results in a price advantage and contributes to a green image. Many customers find that attractive.

6) Production continuity: Insight into energy consumption and needs enables companies to better deal with energy supply problems such as peak loads, power outages or price fluctuations.

7) Longer equipment lifespan: Working in an energy-efficient manner and avoiding overloading means that machines and installations are less likely to be damaged, which extends their lifespan and reduces maintenance costs.

8) Innovation and technological progress: Energy management stimulates investments in advanced technologies such as smart meters and energy management systems. This allows companies to modernize their processes and remain competitive in the market.

9) Better corporate image: Companies that actively apply energy management demonstrate corporate social responsibility, which can attract investors, customers and employees.

MyPlantFloor - EMS

Saving energy is good for the climate and lowers your energy bill. The EMS-module (Energy Management System) provides real-time insight into your energy consumption. It detects waste and collects data for the long term. This allows you to compare consumption during different production runs and make informed decisions within OEE.

No changes to electrical installation needed for implementation.
Data can be processed into reports to analyze trends.
Insight into waste gives you the opportunity to save on energy costs.

More information about EMS production software can be found here.

Inventory management

WMS

Inventory management has a direct influence on efficiency, costs and throughput time within a production process.

1) Efficient material flow: Smart warehouse management ensures that raw materials, components and finished products are available at the right time and in the right quantities. It plays a key role in JIT strategies, where inventories are minimized without halting production.

2) Cost control: Optimal management of stock levels reduces storage costs, capital costs and the risk of overstocking or shortages.

3) Minimizing waste: A well-managed warehouse prevents materials from becoming obsolete, damaged or lost, which contributes to sustainability and cost savings.

4) Improved production planning: Accurate inventory management provides insight into the availability of raw materials, semi-finished products, packaging and end products, enabling better production planning and the prevention of delays.

5) Traceability and compliance: Good warehouse management facilitates accurate administration of incoming and outgoing goods. This is important for traceability and compliance with legal requirements.

6) Increased customer satisfaction: Fast and reliable delivery of products thanks to a well-functioning warehouse contributes to better service and satisfied customers.

MyPlantFloor - WMS

Within the software for production processes, we can use logistics control to improve and simplify your organization's inventory management. This software not only provides insight into the location, volumes and quality of raw materials and manufactured products, but also of semi-finished products and packaging materials.

In general, inventory management in an ERP system is limited to quantities and, to a lesser extent, inventory locations. MyPlantFloor Logistics control does this, so you can also work with scanning. This has numerous advantages:

More accurate picture of inventory
Scanning reduces the chance of errors
Faster order picking
An exact picture of which lot numbers were delivered to whom
Advice on stock and planning production orders for semi-finished products

You can use WMS as an autonomous system, but we usually see it used in combination with Manufacturing Control.

More information about MyPlantFloor Inventory Management can be found here.

The advantages of modular and scalable production management software

Quick results and a competitive price

The MyPlantFloor software is designed to fully digitize your production process. In addition to the basic Manufacturing Execution System (MES), there are various modules available that offer you direct benefits for improving your production efficiency. Thanks to the modular design, you can get started quickly and expand the system step by step.

The most important benefits at a glance:

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One solution for each type of production process

Whether you produce standardized or customized products, the software package adapts effortlessly to your situation.

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Rapid implementation

With a configuration time without complex installations of sometimes only a few days, you are quickly operational and can immediately implement improvements.

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Flexible expansions

Add modules or extra functions at any time.

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Forever Young

Agilitec translates every new customer request into an adjustment to the configurable standard software. This keeps the MyPlantFloor application up to date and guarantees your investment. This allows you to grow along with the latest developments.

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Full scalability

The package grows with you, from a single production line to a fully integrated factory.

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Targeted output and reports

Select the data relevant to you and generate reports that provide insight into performance and areas for improvement.

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Easy to use

Your employees can get straight to work without extensive training, saving you time and money.

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Affordable and effective

The modular design makes the transition to a digital factory accessible to companies of all sizes, without compromising on quality or functionality.

Who is MyPlantFloor suitable for?

Our software has been developed for small and medium-sized production companies, but it is also used by large companies. Our customers are active in numerous sectors, including filling and packaging, injection molding, assembly and batch processing. Do you want to start digitizing or optimizing an existing production process? Our solution adapts to your needs.

Our modular software allows us to support a range of production environments.

Production companies with one or more production lines, whether or not spread over several production locations
Companies that want to start digitizing and want to do so step by step
Production companies with a high variety of products or low volumes
Production companies that operate in highly competitive markets, which means they must respond quickly and reliably to demand without compromising quality
New or revised production processes
Optimization of existing processes to reduce downtime and waste
Companies that want to make informed decisions based on data

Would you like to discover how our software works in practice? Request a demo , a no-obligation quote, or contact us for a personal meeting. We would love to show you how MyPlantFloor can help improve your production process as well.

More about MyPlantFloor

How do you use production software intelligently for the digital factory?

The digital factory 4.0

Introduction to the digital factory

Definition and explanation of the digital factory

Benefits of smart industry

Total solution production software

The digital factory - Manufacturing control | MES

The digital factory - Quality control | QC

The digital factory - Maintenance management | CMMS

The digital factory - Energy monitoring | EMS

The digital factory - Inventory management | WMS

Benefits for production management