Benefits of META Smart Factory
In today’s manufacturing environment, companies need complete, accurate and accessible data to achieve cost-effective productivity.
Meta Smart Factory (MSF) is a scalable solution, will allow you to take quick steps in the following periods after first installation. It connects, monitors and controls complex manufacturing systems and data flows on the factory floor and implements needed package to fill previously detected gaps and help customer to reach their targets.
By MSF solutions, you will analyse many different reports such as OEE, production orders , workstations, employee, cost etc. plant by plant, shift by shift and hourly.
All in One Solution
Meta Smart Factory finds the bottlenecks in production with very special algorithms, in this way production line performance increases, operational cost reduces and asset utilization is maximized and also agility and flexibility increases.
It provides an all-in-one solution, hardware (different types and brand machines communicate in same language) and software that will enable remote monitoring, controlling and digitalization of the entire production process which eliminates manual data collection and accurate data analysis.
With real-time analysis and reports, companies can instantly see what kind of problem they have, what they need to do to achieve their targets and can compare their previous situation.
META Smart Factory provides:
Better Visibility & Decision Making
Visibility of material in inventory is the most important part of continuous production. In competitive environment, the better inventory visibility puts manufacturer the more forward and reliable position in their production field. In order to do that, it is to set up perpetual inventory system which is bound to get real time and dependable knowledge about inventory. Having known real material quantity is a critical issue for companies keen to operate flawless in an end-to-end production.
Automobile industry is main drives the economic growth and its performance is viewed as a reflection of the economy’s health.
Currently, automobile industry is facing various challenges such as cost reduction pressure due to consumer expectations, produce global products at local price, unblemished execution of finish products without line stoppage to avoid huge penalties, demand production management.
Fluctuation in demands needs to be integrated and collaborated with customers demand especially at new product development stage due to additional costs & resources boredom. And also sharing information about the new product is confidential and bounds to the most accurate inventory visibility and entail helping through all supply chain visibility.
Meta Smart Factory gives a real time and reliable inventory solution to solve this all boredom with using artificial intelligence decision making process.
Meta solution links to existing warehouse and goods movement in shopfloor which has capability to make reliable Artificial Intelligence calculation using with maximum machine/man capacity and planning demands. Automatically prepared reports help planner’s decision making process and give foreseeable maximum production opportunities to match clients demand timely and accurately based.
Better Inventory Management
Effectiveness of inventory management is a vital part in the manufacturing organization to be more competitive.
Enterprises can transform their operations using lean practices and technologies – an efficient material flow lays the foundation for sustained competitive advantage.
The result of some researches have shown that the problems of inventory management faced by manufacturing organization were underproduction, overproduction, stock out situation, delays in the delivery of raw materials and discrepancy of records. The factors, timely and accurate warehouse / shopfloor records, reservation planning, knowledge of employees/staff skill have shown to significantly influence the effectiveness of inventory management in small medium enterprises.
Problems are bound to factors can be overcome by Meta solution which can do inventory management by establishing continuous, automated monitoring and rule-based notifications for the material flow to ensure that it goes as planned. The programmed rules detect process deviations – such as bottle-necks, material shortages, or overflows in the in-process inventory. When a rule recognizes that a threshold is exceeded, it automatically raises an alert and sends out a notification to operators who can take the appropriate actions to e.g., prevent bottle-necks, storage overflows, or material shortages.
Enhanced Regulatory Compliance
Regulatory compliance is defined as the set of activities and policies in place in an enterprise to ensure the business activities required to achieve the business goals of the company comply with the relevant normative requirements. It can be defined compliance as ensuring that business processes, operations and practice are in accordance with a prescribed and/or agreed set of norms.
Also regulatory compliance can be consisted of measures and directives, which are implemented by policies, internal controls and procedures and which are modelled for business processes in enterprise. They can be identified three classes of compliance rules: regulations, information technology security standards, and quality standards.
Meta solution is compatible to all enterprise activities and policies and its application format can adapt easily its regulation with securely. Meta has enhanced match with common business terminology in order to adapt easily to provide security and quality standards with the relevant like ISA 95 and 6 sigma or lean production management requirements.
In order to select a good solution it is necessary to have a good understanding of what functionality is needed and exactly what is expected from this functionality at enterprise. Therefore If Meta solution has been selected, Meta team analyze the user requirement specification very easily and carefully. With having ISA 95 and 6 sigma or lean production management standards, Meta help structuring the work that the integration has made successfully and the best solution for MES.
Manufacturing waste will be generated in every manufacturing plant. It can be eight types of waste lean manufacturing in order to seek to eliminate and with five common lean principals, tools and techniques manufacturers around the world have implemented into their manufacturing processes.
Generally manufacturing waste types can be categorized in 8 types which are Defects, Overproduction, Waiting, Non-utilized talent, Transportation, Inventory, Motion and Extra Processing.
Meta solution gives better opportunities to reduce waste to focus on what leads to adding value and helping with reduce defects.
Meta solution provides lower defects with quality management module, protecting over production with better planning management module, avoid waiting manufacturing process by observing machines and creating real time notification, giving talented employee performance reports to see non-utilized talent, protecting rushing good movements in shop floor, warehouse module collects pallets and tasking in time to transportation, real time visibility inventory makes optimize storage and easy to find and move easily via inventory management to prevent extra goods motion and having better quality module ensures minimum scrap and better quality production processing.
Having lean methods, Meta provides the better solution all above which means the better product via improved quality module. The fewer defects means less waste and make the enterprise customer satisfaction.
Productivity is a significant tool for enhancing business competitiveness in the market. Presently it is just one indicator of the competitiveness of the sustainability of the market. That is why productivity concept allows not only keep the company in the market, but also the further development and growth through the use of new approaches to the use of IT infrastructure, data and their integration. Industry 4.0 holds huge potential.
Meta Smart Factory allows individual customer requirements to be met and mean that even one-off items can be manufactured profitably. Having used its Industry 4.0 solution, dynamic business and engineering processes enables last-minute changes to production and deliver the ability to respond flexibly to disruptions and failures on behalf of suppliers, for example.
End-toned transparency is provided over the manufacturing process, facilitating optimized decision-making. Using continuous machine learning process, Meta solution will also result in new ways of creating value and novel business models to each client. In particular, it will provide not only large scale company but also gives start-ups and small businesses with the opportunity to develop and provide downstream services with Meta solution. In addition, Meta solution can be addressed and solved some of the challenges facing the world today in where the machines are such as resource and energy efficiency problems in enterprises, agricultural applications with watering efficiency. Meta solution can enable continuous resource productivity and efficiency gains to be delivered across the entire value network.
META Smart Factory brings:
Enforcing Business Process
The Industry 4.0 has the ambition to revolutionize industry management and business processes, enforcing and enhancing the productivity of manufacturing technologies through ﬁeld data collection and analysis, thus creating real-time digital twins, digital replica of physical objects, of industrial scenarios. Moreover, it is vital for companies to be as “smart” as possible and to adapt to the varying nature of the digital manufacturing. This can be possible by leveraging IIoT in Industry 4.0 scenarios. It can be widely applied in such industries as energy, aviation, manufacturing, transport, logistics and medicine.
The ﬁrst phase concerns the digitalization of the control quality process, speciﬁcally related to the company’s production lines. The use of paper sheets containing different quality checks has been made smarter through the introduction of a digital, smart, and Web-based application, which is currently supporting operators and quality inspectors working on the supply chain through the use of smart devices.
The second phase of the IIoT evolution concerns both digitalization and optimization of the production planning activity, through an innovative Web-based planning tool. Meta solution can make the changes introduced have led to signiﬁcant advantages and improvement for the manufacturing company, in terms of: impressive cost reduction; better products quality control; real-time detection and reaction to supply chain issues; signiﬁcant reduction of the time spent in planning activity; and resources employment optimization, thanks to Meta application of the minimization of unproductive setup times on production lines.
In addition to optimising where existing processes in enterprise, Meta Industry 4.0 solution will also unlock the potential of even more differentiated tracking of both detailed processes and overall effects at a global scale which it was previously impossible to record.
In order to succeed in a global market, it is becoming critical to be able to take the right decisions, often at very short notice. Meta Industry 4.0 solution provides optimized decision-taking opportunities which are end-to-end transparency in real time, allowing early verification of design decisions in the sphere of engineering and both more flexible responses to disruption and global optimisation across all of a company’s sites in the sphere of production.
The overarching strategic goals for enforcing industrial manufacturing processes can be applied with Meta Industry 4.0 solution which are delivering the highest possible output of products from a given volume of resources productivity and using the lowest possible amount of resources to deliver a particular output efficiency. Meta solution allows manufacturing processes to be optimised on a case-by-case basis across the entire value network. Moreover, rather than having to stop production, systems can be continuously optimised during production in terms of their resource and energy consumption or reducing their emissions. Meta smart factory algorithms can be applied to the large quantities of diverse data (big data) recorded by Meta smart devices in order to provide innovative services. There is particularly significant opportunities for enterprises.
Traditionally, paper is used to collect data among various functional areas of a factory has been through the exchange of technical diagram, quality sheets, material check lists, shop floor travelers and so on. These papers circulate with too much space and costly to process. Working on paper makes slow pace of the enterprise to paper traveled in the factory.
Paper based records can have some mistake and lack accuracy, weak traceability and control, at the last, working with them is time-consuming. Even if the company are better organized, some employee might not be, and planner might have problem to track and couldn’t find an important document when he needs.
The main problem with the papers is to make time consuming and not allowed to find it easily and efficient data transfer through enterprise. Bad logging files and needing more comunications has to be made in shopfloor also. This means that wasted time and money that could be gain much more efficiency.
To improve their lack of time based accuracy data, Meta solution can fullfill enterprise’s operation needs using its function without paper. Meta solution can provide workflow automation to define paths for electronic documents to travel automatically. It can be employed “smart” application, which looked just like their paper analogs but could catch errors as data was entered and were able to route themselves to the right work stations.
Meta Smart Factory gives all production information in enterprise and designed to replace traditional paperbased communication. Meta web based application modules are used used to gether on time critical manufacturing process information and other features that can be collected data to need the paperless factory from workstation. Meta solution can collect data from the machines to continually monitor and improve the manufacturing processes leading to increased productivity. It tracks and manages all aspects of a job on the factory floor in realtime.
Meta solution has webbased technologies which are used within functional location as well as in enterprise to be competitive advantages in field of IIOT. Meta technology gives line operators, engineers, and managers a clear real time view of the performance and capability of their processes in a user friendly web application.
With all digitilazation features Meta solution can help to oversee all enterprise areas continues paperless information accuracy, fast, transparency, tarceability data and give cost saving oppotunity without waste of time.
Improving Agility & Flexibility
Some researches shows that internal variety-management strategy in enterprise and external supply chain integration have a positive influence on supply chain flexibility and agility. Customer relationships and variety-management strategies influence supply chain flexibility more than partnerships with suppliers whereas variety management strategies and partnerships with suppliers influence supply chain agility more than customer relationships.
In fact, for external integration in particular, customer relationships influence supply chain flexibility (i.e., reaction capability) rather than agility (i.e., reaction time) whereas partnerships with suppliers influence supply chain agility rather than flexibility. In a high customisation context, close customer relationships are the most effective way to increase dupply chain flexibility, whereas partnerships with suppliers are the most effective way to increase supply chain agility. In a low customisation context, a variety management strategy and customer relationships are the most effective way to increase both supply chain flexibility and agility.
Both flexibility and agility are requisite for the successful operation of organization. Most manufacturing companies are facing volatile and unpredictable demand due to trends such as increased global competition, shorter business cycles and broader product ranges. To survive in this competitive and fast-changing environment, it is necessary to improve flexibility and become truly agile. The required flexibility levels have to consider volume fluctuations, product mix fluctuations and customer lead time requirements. Tools and strategies that enable the supply chain to meet these requirements, without compromising on the unit cost, must be implemented.
For all these requirements, Meta solution is ready to adapt to tomorrow’s competitive manufacturing landscape. It gives best opportunities supply chain cost-efficiency focus and is accompanied by a high degree of agility. Meta can help to take action for continuous flexibility improvement and develop a plan for the future. The plan can be updated on a continuous basis according to changes in customer demands, the production process and the supplier base, in order to work towards an optimized agility level. An important ingredient to facilitating the transformation is to define Meta analyze KPI reports that reflect the flexibility targets. In the analyze reports, performance can be measured shape behaviour, and it is therefore reflected flexibility and responsiveness to customer demand.
A successful manufacturing company is one that can deliver the right product, at the right time and place and at the right cost. To succeed with this in tomorrow´s competitive environment, with its increased demand volatility and more challenging trends than ever, manufacturing companies must be agile. This requires a systematic and cross-functional approach. Meta smart factory solution gives the best and easy way to make successful operation of organization with agile and flexible production and supply chain. Overall, companies can become more agile, as well as can find ways to achieve this with minimal effect on unit cost with meta solution.
Reducing Operational Costs
Digitilazation of a factory can make it to gain much more revenue by means of IIOT Ind. 4.0 MES applications. This depends mainly on the more adaptation of digitilazation all factory managements application, resulting the lesser operation costs as possible. Enterprises, using digital planning with integrated IIOT solution for manufacturing entails combined data from within all factory levels like inventory integrated shop floor activities in customer demand. This level planning improves relationship asset and product plan’s success. Predictive maintenance is to prevent any costly repairs and reduce any unplanned downtime in IIOT applications, using on key factory assets, which uses predictive algorithms to optimise repair and maintenance schedules can improve asset uptime and these can make more revenue value thanks to real time data.
Some studies show that there is good relations between efficiency and operational costs. The more overall efficiency of using digitalization for planning a factory has, the lesser operational costs will be earned average like in operational costs by 3.6% and while increasing efficiency by by 4.1% annually.
Meta solution offers real-time end-to-end planning and horizontal collaboration applications with using cloud-based planning algorithms. Companies that can use Meta modules to become better integrated with horizontal value chain assets, including suppliers and key customers, can be significantly improved efficiencies and reduce inventories, logistics and labour costs. Meta solution with monitoring all production and quality module to reduce time, labour and material waste in real time, company can reduce operational costs and get valued revenue instead.
Maximizing Assets Utilization
For manufacturing companies, predictive maintenance is a game-changing strategy, through which they can harness the power of their Industry 4.0 technologies to monitor the real-time health of their assets, foresee asset malfunctions and breakdowns before they happen, and formulate optimal maintenance schedules.
Meta monitoring technology affords to collect manufacturing information about machine activities and performance not available through other means. Meta can gather all data flow from machinery to information from other points in the routing such as quality collection and rework areas in the real-time.
With predictive maintenance-based planning and operations, Meta solution can address and overcome some machine problems before they become serious in order to avoid production disruption via maintenance system application. With using machine learning algorithms Meta analyzes overall machine performance trends and can show machine status and just in case measuring point is passing over, can trigger automatic order to pass production to other available machine and to solve maintenance problem it can open automatically. Having with this function of enterprise it can be utilized all machine assets to be competitive on maximizing of production assets in real-time
Thanks to Meta predictive maintenance and planning functions, the management level business leaders have access to summary views of factory, and organized, directed diagnostics for real-time evaluation of the performance of the factories.