Dynamic Raw Material Generation and Traceability

Challenges

With the technical development steps outlined in the section below, it will be possible to operate the manufacturing processes with better material traceability, while at the same time achieving greater efficiency and less scrap. MSF System will allow managers to instantly display and analyze information from shop floor in real-time, thus keeping them informed of the current state of production, supporting decisions and drawing conclusions.

Scenarios and Solutions

The scenarios that need to be demonstrated during the implementation period vary according to the final product type. Thus, we have depicted 4 different scenarios and a short summary for each of them is as follows:

Type 1: Two raw materials are rewound and cut separately to form sub-materials that will be laminated together to form the final product.

The sub materials’ width will be limited by a maximum width which will be entered into the system.

The sub-materials can be created from different raw materials and can have different batches, all of which the system will take into consideration when calculating the best case scenario to consume the raw materials.

In between, job orders are also created for the core materials that will be used to rewind the tapes on them.

During the 4^th job order, the lamination and cutting operation will take place to form the final product. The final step will be packaging.

Type 2: Similar to type 1, the main difference is that cutting cannot be done with one operation for the whole roll, thus it needs to be cut piece by piece for each final product. Before cutting, lamination is also done separately on a different machine.

Type 3: Splitting operation is done to the adhesive at the initial steps, to separate the layers of the raw material.

Type 4: Die cutting operation takes place before the final product is created. Input rolls are laminated and either shape are formed on the final product, or one of the layers is cut

Results

Different raw materials (with different batches) can be used to form the same final product. Thus, MSF will provide full traceability to differentiate which materials were consumed for each final product.

After the first cutting operation takes place, the unused remaining materials are generated as new sub-materials with automatic sub-batches, so that they can be re-used for different final products that satisfy the width/length condition.