All types of paperbased records for operators (start-up checklists, downtime records, production volumes, operator logs), for quality inspectors, for lab test results and hygiene and food safety can be included and monitored in the HAI database. Thus creating a paperless plant.
An automatic Planning system is in place to create an optimum Planning for your Production Orders.
A real-time Adherence to Plan overview shows exactly in Production is performance in line with the original Planning.
Operators can start production orders and monitor the volumes produced and downtimes incurred, and eventually record the completion of a production order which can be automatically posted in the ERP business software, like SAP.
Quality inspectors can carry out “Batch Release” when quality inspections are compliant.
Complete tracking & Tracing is provided from packaged goods back to packing orders, production orders and raw materials. Alternatively, you may track and trace forward, for instance in which batches a specific batch of raw materials has been used.
The HAI software has been developed using SAP and Microsoft Technology. Certified by SAP and awarded as “Cool Vendor for Manufacturing” by Gartner, HAI has received recognition for its technological and functional achievements. For Internet of Things and Smart Factory Solutions, it is vital to work with the latest cloud technology applications.
Web services are used to collect the data in a central cloud database. HAI has developed a lot of know-how and tooling to connect all types of systems to its central cloud database: this may concern data coming from SCADA/PLC (process control systems), in-line test instruments, quality testing instrument connections, or other databases.
Connections to ERP business systems, like SAP, are done by reading data from ERP (production orders, quality inspections, planning, etc.) and providing feedback on production order completion, and quality inspection results. ISA-95 compliance facilitates vertical and horizontal integration
The software is available in the Cloud in a Software-as-a-Service subscription model, or, alternatively, it can be installed on-premise.
The HAI software contains information on product quality, processing conditions (temperatures, flow rate, speed, time of residence, etc.) and production volumes. This information is shown in real-time and matched against specifications. Thus, compliance of quality, processing and production is monitored in real-time.
Dashboards give real-time information on trends and Key Performance Indicators (KPI’s) like OEE (Overall Equipment Effectiveness), Quality Performance, Adherence to Plan, etc.
OEE metrics are calculated in real-time to track speed losses, quality losses and downtime losses. Analysis of downtimes, speed- and quality losses is important to understand how to improve the Availability Rate, Performance Rate and Quality Rate.
Trending of quality characteristics, process parameters, and in-line test results helps operators and process engineers to prevent out of spec and improve product quality consistency.
Statistical Process Control features support further process improvement.
Smart Factory Apps and Industry Analytics-as-a Service are developed for certain specific purposes. For instance, a complex and capital-intensive process like a spray-drying installation, can be analyzed, and the results can be used in a “smart factory app” to monitor the process and identify anomalies.
Alternatively, Analytics-as-a-Service are typically used in a broader context, like the monitoring of supplier raw material data, or customer application data.
For the development of this type of applications, it is vital to have a cloud connectivity infrastructure, a flexible database, a powerful SAS Analytical Platform, Data Analysis experts and industry expertise. Customers don’t need to make high up-front investments in infrastructure and software and can simply benefit from a monthly fee as part of the “As-a-service” subscription model.