Shop Floor Data Collection
HYDRA Shop Floor Data Collection
Optimum Support for Production
Today, manufacturing companies have to cope with shorter delivery times, smaller production batches and continuously increasing cost pressures. As a result, real-time information becomes more and more critical for operations closely linked to production, such as work scheduling and shop floor control and especially for the production manager.
HYDRA shop floor data collection provides timely and comprehensive information on production processes.
This enables HYDRA users to accomplish objective cost control and final costing.
Organization and Planning
HYDRA-BDE helps production-related departments to enter data according to their individual specifications and, as a result, to use them for planning and organization purposes:
• Definition of production managers’ areas of responsibility and cost centers
• Download of orders and operations from ERP / PPS systems
• Creation, maintenance and administration of work plans and orders in addition to the ERP / PPS system
• Printing of shop floor papers, labels and time tickets
• Generation of split and milestone operations as well as merged operations
• Sequencing, graphical order scheduling, material requirements and setup lists
• Consideration of alternative units (quantities, weights, areas, running meters) including individual rules of conversion
• Configurable calculation formulas for remaining running times
• Definition of order types for differentiated handling of various kinds of orders (production, overhead cost, project or capacity orders)
Data Collection
In HYDRA-BDE, data relating to orders and articles can be entered in such a way that,
on the one hand, less effort arises for operators and, on the other, comprehensive overviews on the current situation in production as well as extensive reports are available on time:
• Logon / logoff, interruption and partial confirmation/uploadof operations or orders
• Recording of quantities (yield and scrap) as well as scrap and interruption reasons
• Configurable plausibility checks, e.g., regarding underdelivery and over-delivery
• Collection of personal or group related times
• Gathering of production and downtime reasons to freely definable resource performance accounts
• Special functions for machining centers (order pool)
• Capturing of material data and consumption data
Operators and setters enter shop floor data using individually configurable and ergonomic user dialogs.
Barcode devices, pre-defined selection lists and online checks make sure that data are entered faultlessly. In addition,
all important order-related information, such as target specifications, BOM, inspection instructions and work instructions
or drawings may be opened directly – which is the first step towards paperless production.
Current Order Information
HYDRA-BDE shows all important order-related pieces of information in detail and in real time, e.g., the current status, interruptions, order progress etc.:
• Order pool and to-do lists for orders (tabular and graphical)
• Order overview with prepared, running, interrupted and terminated operations
• Current status of operations and orders
• Order progress and calculation of remaining run times
• Concurrent cost control and determination of wait times
• Online comparison of targets and actual values
• Display of drawings, inspection instructions, bills of material and other order-relevant data
Generation of Evaluations / Reports and Statistics
HYDRA-BDE evaluates data, creates statistics and, as a result, provides information by which problems in the production process can be recognized and taken into account for future production:
• Terminated orders and schedule violations
• Order-related production, downtime and setup times
• Foreman’s checklists and correction of collected data
• Shift logs, including target / actual comparisons of quantities, times and other parameters
• Order, article and scrap statistics
• Order and article profile with comparison of order duration, processing time, production time, downtime and wait time (tables and graphics)
• Reports about lead times, wait and transport times compared to production times
• Long-term archiving of order data
• Uploads of current data to ERP/PPS
The order shift log provides an overview of orders processed in the selected shift.
The order overview shows the current status of production orders. For multi-level orders production progress can be viewed for all relevant operations.
The statistic provides information about operations that have producedscrap. A hit list shows which workplaces have caused most of the scrap.
