Smart Manufacturing Management Solution

• Defined by process

  Defines management elements such as equipment, materials and operators for each unit process

• Tracking and control

  Tracks and manages all materials against predefined specifications

• Digitalisation

  Digitalises detailed execution results and per-process measurement data for each product

• Systematic management

  Manages every resource in the plant systematically

• Interfaces

  Interfaces for integration with other systems

• Knowledge-based information systems for shop floor management are inadequate
• No integrated functionality across production activities
• Information is not shared across plants, departments, processes and workflows
• Production progress is hard to track stage by stage
• Raw material and part inputs do not match physical stock
• Limits on providing and collecting the information the shop floor needs
• Limited flexibility when plant conditions change suddenly
• Hard to see the shop floor clearly and respond immediately
• Need for a system that shows the whole floor at a glance and supports decisions
• Limited ability to close the gap between ERP production requirements and actual results
• Managers spend 25 to 35 percent of their time checking and correcting shop floor data

• 01

  Integrated production management
  • Integrates with existing systems such as ERP
  • Manages material receipt and issue by barcode, keeping raw and sub-material movements clear
  • Handles everything from production planning to work orders, process control and performance entry at the right management unit
  • Quality control built on production history
  • Automates receipt and shipment with wired and wireless scanners and PDAs
  • Collects and analyses shop floor information so operators and managers can decide quickly on clean data

• 02

  Quality control and decision-making
  • Covers the full production cycle, from order-driven start to final product inspection
  • Collects production results, operator activity, equipment operation and product quality data in real time
  • Aggregates, analyses, monitors and controls the production process
  • Establishes a high-quality, profit-oriented production system
  • Gives an accurate, real-time view of production status on the floor
  • Built around the industry, the site and the management needs of each company

• Improvement

  Better quality through systematic production management · Higher plant efficiency through standardised information · Accurate root-cause identification and faster response to losses

• Decrease

  Shorter cycle and lead times · Less paperwork between shifts · Lower defect rates · Reduced work in progress

• Management

  Automated real-time data collection and statistical process control · Greater visibility so operators, managers and executives work from the same picture · Real-time monitoring of WIP performance by equipment

• Smart

  A convenient, intuitive working environment that is easy to pick up

• Speed

  Efficient process management for fast task handling, with simple settings that make rollout easy

• Security

  Strict security technology protects information and keeps customer assets safe. A disaster-resilient data centre keeps the service running through failures, delivering a highly available environment at low cost

• Integration

  A unified UI and unified data make operations and management flexible and efficient

• Cost Reduction

  Use only the specification, features and duration you need as a service, cutting initial deployment costs sharply. Managing software and data together also makes updates and data maintenance more efficient

• Flexibility

  Scale computing resources up when you need them and back down when you do not

• Companies that need systematic management but have limited staff to run the system
• Companies for which a large in-house build is financially out of reach
• Companies that need an MES they can adopt quickly and simply

• Master data management
  • BOM management
  • Routing management
  • Terminal management
  • Item information management
  • Vendor information management
• Production management
  • Work order management
  • Performance management (production results, LOT tracking, monitoring)
  • Inbound management
  • Outbound management
  • Outsourcing management
• Material management
  • Purchase order management
  • Delivery management
  • Inbound management
  • Outbound management
• Inventory management
  • Inventory management
  • Transaction management
  • Monthly inventory management
• Stocktaking management
  • Material stocktaking
  • Production stocktaking
  • Product stocktaking
• Sales management
  • Order management
  • Inbound management
  • Outbound management
• Quality management
  • Master data management
  • Incoming inspection management
• Field management
  • Performance registration
  • Performance inquiry
  • Delivery registration
  • Delivery inquiry
  • Outsourcing management
• Equipment management
  • Equipment information management
• PDA
  • Inventory stocktaking
  • Sales outbound registration

• Mould management
  • Master data management
  • Mould history management
  • Spare parts management
• Field management
  • Performance registration (mould)
  • Self-inspection registration
  • Patrol inspection registration
  • Daily inspection registration
• Quality management
  • Inspection results management
  • SPC management
  • Gauge R&R management
• Equipment management
  • Daily inspection management
  • Maintenance work management

• Economic efficiency

  Less infrastructure to build out, from power to network · Lower hardware operating and maintenance costs · Shorter MES deployment cost and timeline

• Convenience

  Use MES across operating systems and devices, from PC to mobile · Connect without limits of time or place · Check and manage work status in real time

• Expertise

  Professional management and support for hardware and systems · Stronger security and incident response · Continuous monitoring and support that keeps operations efficient

• Efficiency

  An always-on collaboration structure · Better data reliability and processing speed · Easier information sharing across teams

• Monitoring

  Continuous monitoring of quality information

• Automated tracking

  Automated quality LOT tracing

• Analysis

  A range of analysis functions for identifying the causes of quality issues

• Reporting

  Generates quality reports, including defect cause reports

• Master data management
  • Item master
  • Vendor master
  • Department information
  • Monthly unit price registration
  • Defect code registration
  • Validation check item registration
• SPC process control
  • SPC standard registration
  • SPC standard inquiry
  • SPC performance registration
  • SPC performance inquiry
  • X-bar management
  • Process capability management
• Drawing management
  • Drawing registration
  • Design change and revision management
  • Drawing status inquiry
• Measuring instrument management
  • Standard management
  • Measuring instrument master registration
  • Measuring instrument master inquiry
  • Instrument plan and performance registration
  • Calibration schedule and cost
  • Instrument calibration status
• Development management
  • RFQ and development request summary
  • Development phase registration and setup
  • Development registration
  • Progress management registration
• Defect management
  • Defect registration
  • Defect status inquiry
  • Monthly defect status
  • Annual defect status
• Inspection management
  • Initial, in-process and final inspection management
  • Initial, in-process and final standards registration
• Periodic parts inspection
  • Major parts management
  • Periodic parts inspection plan registration
  • Periodic parts inspection summary
  • Periodic parts inspection approval
  • Periodic parts inspection inquiry
• Corrective actions and reports
  • Receipt of corrective action requests
  • Corrective action plan registration
  • Corrective action plan review and approval
  • Validation check
  • Past problem management
  • Application status of past problems
• Reliability test management
  • Reliability test name registration
  • Reliability test standard registration
  • Reliability test plan inquiry
  • Reliability test plan inquiry (by test)
  • Reliability test analysis request form
• 4M change management / ISIR
  • 4M change notification
  • 4M change reception (material)
  • 4M change reception (quality)
  • 4M change notification response
  • 4M change notification results inquiry
  • ISIR registration
• Supplier quality
  • Corrective action reception
  • Corrective action plan registration
  • ISIR/4M
  • Periodic inspection registration

• Reliability

  A working quality management system earns customer trust

• Stability

  Consistent quality and a stable quality baseline

• Competitiveness

  Lower defect rates and stronger product competitiveness

• Customer response

  Respond to customer requirements quickly and accurately

• Information analysis

  Collects, analyses and monitors shop floor information in real time

• Production data collection

  Production data can be collected in semi-automatic or fully automatic mode

• Mobile sales management

  Sales work can be handled anywhere, anytime

• Customisable dashboards

  User-configurable dashboards show production status and performance at a glance

• The existing system is not usable in practice
• Production performance data is hard to manage
• Registering defects is cumbersome
• Production progress is hard to see
• Data for cost management is not reliable

• 01

  ERP integration
  • Integrates with existing information systems and ERP to receive production plans automatically
  • Turns the received plan into production instructions
  • Feeds shop floor results and quality data back to upper-level systems in real time
  • Connects to major ERP systems in Korea and abroad

• 02

  Master data management
  • Receives master data from upper-level systems for use in MATE-POP
  • Manages what upper-level systems do not cover, such as equipment, failure and defect codes
  • Runs standalone when no upper-level system exists or it is incomplete
  • Builds production plans and schedules and takes in master data on its own

• 03

  Production status management
  • Production results by product, process, work order and time period
  • Performance analysis against targets
  • Real-time shop floor status that ERP systems typically cannot provide

• 04

  Quality data analysis
  • Defect occurrence and defect rates by product and by resource
  • Top 10 defects and their share of total defects
  • Rework and scrap analysis
  • Defect trends by date and by resource
  • Real-time analysis of quality data as it arises, for effective quality control

• 05

  Equipment management
  • Graphs equipment faults, the top 10 breakdowns, utilisation rates and failure trends by type
  • Serves as the basis for maintenance planning
  • Collects breakdown and downtime data from the floor in real time

• 06

  Productivity analysis
  • Attendance management and labour input analysis for shop floor staff
  • Overall productivity analysis
  • Analyses large volumes of data in real time and presents it in multiple views

• 07

  LOT management
  • Precise LOT tracking for accurate history management
  • Forward and backward LOT tracing
  • Tracing of shipments from the same LOT and of the same material LOT

• 08

  Production monitoring
  • View and monitor shop floor conditions in real time
  • A graphical screen that mirrors the production line itself
  • Connects to PLCs and other control devices on the floor to collect data
  • Works with HMI (MMI) software from Korean and overseas vendors
  • Monitor in real time from outside the plant over the internet

• 09

  Production dashboards
  • Monitoring screens laid out like the actual equipment on the floor
  • Detailed monitoring screens for each machine
  • Materials, sales, WIP, inventory and movements at a glance
  • Understand production status without walking the floor

• Real-time shop floor monitoring

  Manage equipment failures and downtime · See work delays and material shortages · Minimise idle time using data aggregated by machine, operator and employee ID · Build long-term plans and know-how on a secured production history · Check WIP on the floor

• Reliable data

  Production results are processed in real time, which raises data reliability

• Raw material and finished goods management

  Inventory, movement and outsourced stock management for raw materials and finished goods

• LOT traceability

  Covers everything from materials to sales, customer shipment and post-shipment returns

• Customer satisfaction

  Higher customer satisfaction through shorter response times

• Shop floor problems identified

  Respond quickly and flexibly to issues such as yield, equipment utilisation and product quality

• Cost reduction

  Cuts the cost of recording, searching for, collecting and analysing information

• Missing operator inspection records
• Records entered all at once after the fact
• Falling data reliability
• Loss of handwritten records
• Quality system cannot be sustained
• ISO/TS/SQ certification out of reach
• No way to prevent defects at the root
• Inherent risk of lot-wide defects
• Rising cost of defect-related losses
• Timing of defects cannot be identified
• Root causes of defects cannot be traced
• Large-scale defects occur and escape to the customer

• 01

  Better measurement entry

  Measured values registered on handheld devices are transmitted to and stored in the system

• 02

  Measurement history management

  Monitoring screen for initial, in-process and final product management

• 03

  Inspection status on demand

  Check inspection progress at any time

• Stronger basic quality

  Improving how initial, in-process and final products are managed strengthens basic quality control

• Statistical control

  The database makes statistical process control (SPC) possible

• Traceability

  Storing measured values in a database secures traceability of quality history

• No missed inspections

  Real-time monitoring prevents missed inspections and enables rapid action on process defects

• Large-scale defects prevented

  Interlocks (alarm/stop) on missed inspections or abnormal measurements keep large-scale defects from escaping

• Efficient process management

  Equipment and software developed for local conditions replace imported systems and make process management more efficient

• Automation that is easy to use

  Work that used to be manual becomes straightforward and convenient for operators

• Efficient compounding

  Automated process control keeps the compounding process under precise, efficient management

• 01

  Monitoring

  Collects data from the process in real time and presents it visually, covering process status, alarm management and anomaly detection

• 02

  Test management – SPC

  Collects test data in real time to analyse process anomalies and charts quality indicators

• 03

  Master data program menu
  • Material registration
  • Operator assignment by equipment
  • Small-quantity chemical setup
  • Carbon oil setup
  • Communication terminal setup and more
  • Master data settings can be registered and queried

• 04

  Compounding management program menu
  • Compounding formula registration
  • Compounding formula printing
  • Bulk material change
  • Compounding cost calculation
  • Compounding weight tests and more can be registered, viewed, edited and printed
  • Prevents the errors that come with manual work
  • Raises productivity by preventing operational mistakes

• 05

  Work management program menu
  • Work order registration
  • Work order status
  • Weighing daily report
  • Weighing detail status
  • Weighing stock status
  • Weighing process stock
  • Weighing work status
  • Automatic weighing records
  • Mixing work status
  • Mixing work details (mixing work history)
  • Mixing process chart
  • Mixing process monitoring
  • Roller work status
  • Roller work details (roller work history)
  • Roller work chart
  • Curing room inbound status
  • Stock inquiry by expiry date
  • Curing room outbound status
  • Curing room temperature and humidity
  • Inbound weight checklist
  • Material usage status (by period)
  • Material usage status (monthly and annual)
  • Monthly and annual work performance status
  • Work progress status by lot

• 06

  Test management program menu
  • Rheometer basic data registration
  • Mooney viscometer basic data registration
  • Tensile tester basic data registration
  • Specific gravity and hardness basic data registration
  • Physical property test criteria
  • Rheometer result registration
  • Mooney result registration
  • Tensile result registration
  • Hardness and specific gravity result registration
  • Rheometer result correction
  • Mooney result correction
  • Tensile result correction
  • Specific gravity result correction
  • Hardness result correction
  • Physical property test daily report
  • Physical property test daily report by period
  • Physical property test statistics
  • CPK management

• Better ways of working

  Moving from manual work to automation raises operational efficiency

• Better working environment

  An organised workplace gives operators a better environment

• Fewer work errors

  The fool-proof system rules out weighing errors caused by manual mistakes

• Real-time visibility

  Check work orders and shop floor activity in real time

• Accurate data management

  Materials, customers, compounding data, work orders and work records are managed accurately and can be used for business analysis

• Stronger competitiveness

  Lower defect rates, higher productivity and stronger competitiveness in the market

Fool-proof system: a design or state that keeps an item reliable and safe even when an inappropriate action or human error occurs. It secures quality and makes LOT tracing of defective products possible, from parts through to finished goods.