SYSCON PlantStar provides Manufacturing Execution Systems (MES) solutions that collect Production and Process data for use by manufacturing, quality control, management, accounting and financial systems. Traditionally Manufacturing Execution Systems provide users and management teams with key information about the manufacturing process as well as the Overall Equipment Efficiency (OEE) of the equipment being monitored.
When you need to know everything that’s happening with your production activities and process variables, you need an MES system that delivers the right functionality. From drag-and-drop job scheduling to real-time dashboard reporting and customizable alerts, PlantStar's manufacturing execution system is designed to help you do what you do best. With a full range of capabilities and continuous updates, PlantStar's MES software has the solutions you and your company need to maximize overall equipment effectiveness (OEE). It’s time to reach your full potential.
Get insight into job-specific details on every machine so you can keep track of upcoming projects, potential downtime, reducing scrap and create your customized reports in real-time. PlantStar's MES features puts you in control by allowing you to customize your MES system.
Job Scheduler
Job Summary
Job Setup Sheets
Customizable Charts and Reporting
Real-Time Dashboards
Downtime and Scrap Reporting
Instant Alerts
Defect Collection
Labor Tracking
Material and Tool Tracking
Simplify job scheduling with a drag-and-drop tool that makes it easy to move projects. The MES shows the current time and tools being used for specific projects, and allows you to update the tools and resources or switch the order of projects in order to avoid collisions.
The job summary screen gives you a quick, up-to-date picture of what is happening on any machine, even those that are not connected to this DCM. With the easy-to-use drop-down menu, you can quickly access important information on a desired machine and make changes to current and future jobs with a touch of the screen.
Easily access machine setup and miscellaneous summary information. Setup sheets can include training videos, documents, part images, and more.
Eliminate guesswork as you drive change and implement best practices as a result of data at your fingertips. PlantStar lets you create charts based on your own reporting in real time and auto-schedule report delivery directly to email inboxes, printer, or network folders.
A web based system allows you to view real time charts, reports, and all machine status from any device. Large Screens are used throughout the facility to show data in real-time.
Get alerts when your machines go down and maintain a record of each occurrence. The system tracks the top causes of downtime for each machine and displays the percentage of time taken up by each down. PlantStar 4.0 comes with unlimited down, reject, assist reasons.
Simplify job scheduling with a drag-and-drop tool that makes it easy to move projects. The MES shows the current time and tools being used for specific projects, and allows you to update the tools and resources or switch the order of projects in order to avoid collisions.
Conduct root-cause analysis to improve quality and eliminate warranty costs so you can reduce product recalls, revenue loss, decrease in customers, and damage to your brand. PlantStar prioritizes defects and charts them out in real time so you can immediately view all your defects for any running job or specific shift. Additional features include unlimited user configurable defect reasons, repair or scrap disposition, and ERP solutions integration.
PlantStar Labor Tracking is designed to collect, report, and forecast labor hours by machine, job, shift, or employee. Labor information is collected and tracked by personnel logging in and out of machines from a DCM or HMI. Employees can be logged onto one or more machines at the same time depending on the category work being done. For this reason, PlantStar Labor Tracking is not typically used as a time and attendance system. It will provide a window to where and how labor is used on the shop floor. It can also report time spent by support personnel at a machine. As a job history is developed the job history labor reports can be used to forecast staffing requirements on a shift or weekly basis. The Labor Tracking feature provides the ability for Operators to log their actions using Process Journal entries, providing an audit trail for activity within the PlantStar MES system. All of this data is stored in a secure database within the PlantStar APU server. This data can then be used for various management information system functions including review, analysis, audit, and reporting, including upstream and downstream integration with ERP systems and functions.
Single Material Lot Tracking -MATL-LOT/S
Single Material Lot Tracking allows tracking of consumption of one material per machine
using the operator input at a touch screen DCM. The lot number identifies the material.
Consumption tracking, is supported and forecasting is enabled as well.
Multiple Material Tracking - MULT-MTL
Multiple materials can be tracked with this option. Use of each material can be
tracked and forecasting of material demand is supported to improve operations and control.
Multiple Material/Multiple Lot Tracking - MAT-LOT/M
Up to four component materials and four lot numbers can be tracked with this option. Use of each material and lot can be tracked and forecasting of material demand is supported to improve operations and control.
Take advantage of integration features, tracking capabilities, and a variety of other functionalities that help streamline your processes and deliver quality products.
Operator Tracking
Labeling and Barcoding
ERP Integration
Remote Monitoring
Real-Time Data
Voice Output
Process Journals
Process Variables
Tools
Tool Maintenance Events
Eliminate the guesswork in associating specific users with completed action events. With PlantStar 4.0 operator tracking, users can quickly identify operator action events using simple track-and-trace capabilities.
Reduce the percentage of recalls due to product label errors with labeling and barcoding capabilities that strengthen compliance, increase productivity, and reduce operating costs while focusing on product traceability.
PlantStar 4.0 is a fully web-based manufacturing execution system. See the status of your production equipment, OEE, parts per hour, reject % etc. wherever you are with remote monitoring functionality from any device connected to the internet.
Your machine operators need to be able to access timely data in order to make quick decisions, and PlantStar’s MES provides that and more. Get an up-to-date look at your most important metrics and KPIs on a single, customizable screen. With the Machine Status view, you have insight into the real-time status, efficiency, and production data for any machines you choose. Plus, you can access simplified, color-coded charting with historical and real-time process variable data.
A PlantStar system configured with the Voice Output Option is able to broadcast messages
relating to currently monitored exception conditions such as:
These messages can be heard on speakers or public address systems.
The PlantStar Process Journal program is a web-based program designed to provide the shop floor personnel with a method to record changes made to a process being monitored by the PlantStar system.
The PlantStar Process Journal system provides an interface for users to record and track equipment maintenance, outages and other problems, as well as the resolutions to those issues. This feature is used in conjunction with our labor tracking option. The data is time-stamped and associated with an individual job, shift and employee. It also has a totally browser-based user interface. So anyone on your network will be able to view the data.
Types of process variables are used to monitor characteristics which are repeated with every machine cycle. Examples are pressure, temperature or time duration process variables.
Some process variables are collected only when new readings are provided by the operator. These types of process variables are used to monitor something which is sampled at irregular intervals. Examples are measurements of sampled parts such as weight or dimensions.
Whenever a reading is collected, it is compared to the process limits which have been defined for a job. If the reading is out of bounds, a process violation is flagged. This violation is displayed on the monitoring windows as a process exception.
Their behavior can be graphically displayed on any work station or at the relevant EL/TS DCM. A profile is a set of up to 500 readings of a single process input channel collected during one machine cycle. The input channel can be sampled as fast as once every 10 mS. Limits may be set for the minimum and maximum values (similar to process limits) to flag a process violation. Again, any violations are displayed on the monitoring windows.
A Tool in the system is something physical and unique, and has an associated serial number. Even if there is a similar tool, it is not physically the same tool. A Tool has information tracked. For example, time since it was first pulled out of a box (lifetime), time that it was ran on all the machines (runtime), and the number of cycles that it has been through. Having a similar Tool is what we call Tool Type. You may have 3 tools that are all of the same nature and can be swapped out interchangeably. These 3 tools would all use the same Tool Type.
A Tool Type Group is a group of Tool Types, that is used on a job before it starts running because in many cases you don't know which Tool of a particular Type you want to use until the job actually starts. When you start the Job you can select which Tool will be used and the system will present you with the available options based on the Tool Type Group Selected.
This is used after a Tool Maintenance Event has been completed. The system can then use the duration information to trigger Alerts prior to the next Tool Maintenance event.
Process Monitoring allows process variables to be created and tracked during a job. The data can then be viewed on charts or spreadsheets in real-time.
Stay up to date about the process variables that go into your projects, with the ability to easily make adjustments as necessary. If defined for a machine, unlimited process variables can be monitored. Most process variables are collected once per machine cycle. These types of process variables are used to monitor characteristics which are repeated with every machine cycle. Some of the most common examples are pressure, temperature or time duration process variables. When it comes to process monitoring PlantStar's manufacturing execution system is unmatched.
Physical or Trigger-Based Process Variables
Tailor Process Variable Limits
Process Variable Chart Viewer
Process Trend SPC
Process Summary
SPC History
The Process Table
The Process Graph
Process Select
Some MES systems limit the user on the number of process variables, but with PlantStar you can input any number of PVs and process variable profiles.
Use PlantStar to set upper and lower limits to your process variables and easily adjust as production needs change.
View live readings of KPIs including pressure, temperature, injection position and much more in real time. Tweak the chart configuration on the fly for a truly granular view into the health of your machines.
Stay up to date about the process variables that go into your projects, with the ability to easily make adjustments as necessary. If defined for a machine, unlimited process variables can be monitored. Most process variables are collected once per machine cycle. These types of process variables are used to monitor characteristics which are repeated with every machine cycle.
Stay up to date about the process variables that go into your projects, with the ability to easily make adjustments as necessary. If defined for a machine, unlimited process variables can be monitored. Most process variables are collected once per machine cycle. These types of process variables are used to monitor characteristics which are repeated with every machine cycle.
Stay up to date about the process variables that go into your projects, with the ability to easily make adjustments as necessary. If defined for a machine, unlimited process variables can be monitored. Most process variables are collected once per machine cycle. These types of process variables are used to monitor characteristics which are repeated with every machine cycle.
Stay up to date about the process variables that go into your projects, with the ability to easily make adjustments as necessary. If defined for a machine, unlimited process variables can be monitored. Most process variables are collected once per machine cycle. These types of process variables are used to monitor characteristics which are repeated with every machine cycle.
Stay up to date about the process variables that go into your projects, with the ability to easily make adjustments as necessary. If defined for a machine, unlimited process variables can be monitored. Most process variables are collected once per machine cycle. These types of process variables are used to monitor characteristics which are repeated with every machine cycle.
The Process Select screen allows for monitoring up to fifty process variables that may be defined for the currently running job on the selected machine.
It provides a quick visual reference to monitor the process exception state for a machine. If the last value recorded for a process variable is above the higher limit or below the lower limit defined for the job, that process variable is highlighted according to the following default color scheme:
· Red - value is above the higher limit
· Blue - value is below the lower limit
If a process variable exceeds its defined limits for the job, the machine will be put in the process exception state for that cycle which will be reflected by the color conventions used in the lights frame.
We chose SYSCON PlantStar to be our MES system as it provided us with a wealth of production and process information, including scheduling, product specification, OEE data, labor and process tracking in a flexible, friendly and real time environment that assist us in achieving our operational excellence goals. Over the years (20+ years) PlantStar had validated that we made the right decision by providing us with great customer service and support coupled with leading edge technology. I would highly recommend their services to any other company that is in the market for MES system
With PlantStar, we’ve reduced our internal and external corrective action reports by 92.8%, with major gains in first-time quality improvements and customer satisfaction. An initial savings of $400,000 was realized within five months of implementation.
PlantStar has proved vital to our Manufacturing efficiency and has introduced the ability to stay connected remotely to make key real-time decisions. It has changed the way we operate!
Contact us today to schedule a demo!
Address:
1108 High St. South Bend, Indiana 46601
Phone:
+1 574-232-3900