PLANT MANAGEMENT
manufacturing. However, Southco, a leading manufacturer of engineered access hardware solutions, has been building its smart factory since 2007, when the company introduced the Epicor Mattec Manufacturing Execution System (MES).
Epicor provides industry-
manufacturing, distribution, retail and services organisations. The Epicor Mattec MES enables companies to monitor their production and process manufacturing operations in real-time, allowing them to reduce scrap, waste and machine downtime, as well as improve cycle (OEE), productivity and automatic part The introduction of the MES marked the beginning of Southco’s global transformation of the way that it manages production and process control through the use of smart technologies. Originally, it was introduced solely as
production control software that was used to track the inputs and outputs of the injection moulding machines at Southco’s Worcester, UK manufacturing facility. Over time, the team worked closely with Epicor to further develop the system to incorporate improved functionality that requirements. A decade later, Southco now uses the software to create a visual factory. sources, the MES organises all of the information into a visual dashboard that helps to support the improvement in manufacturing processes through continuous analysis. By observing both production control and process control simultaneously, the business can constantly improve the quality of work. The main driver behind implementing
Industry 4.0 was to improve internal operations processes, by developing them in line with market conditions and available technologies. Building smart technology into the facility allowed Southco to better understand its products and processes while enabling the workforce to be more accurate with deliverables. One example where smart technology has enhanced operations is through
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An MES allows companies to monitor their production and process operations in real time
product quality evaluation: before a plastic injection mould opens, the system alerts the operator to whether the end product is good or bad. This translates into a better product for the customer, as quality monitoring is built directly into the process (rather than having to manually inspect each batch). Having processes has enabled the business to improve all aspects of assembly and has given actionable insights from data analytics.
In contrast to commonly held
perceptions, the introduction of smart technologies and Industry 4.0 does not need to involve a revolutionary change to the business and its processes. As demonstrated by Southco, when working with a trusted supplier, businesses can take gradual steps towards creating a fully connected smart factory.
CENTRAL TO THE BUSINESS For many manufacturers, one of the greatest blocks to Industry 4.0 is the prospect of implementing it in the the potential cost and the the implementation period are perceived as major obstacles. However, Southco has experienced a smooth progression towards Industry 4.0 by embedding its smart technology right at the heart of its manufacturing facility, rather than treating it an add-on. The system links with other businesses systems such as SAP, with the exchange of information between the two
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