Vegam Solutions

Australia Melbourne China Humen Jiangsu Panyu Shanghai Yantai India Chennai Indonesia East Jakarta Jawa Barat Pasuruan Japan Kakogawa Shiga Yokohama

Malaysia Shah Alam New Zealand Wellington Philippines Cabuyao Singapore Singapore South Korea Seoul Thailand Bang Pakong Vietnam Bien Hoa

Solutions by Deployed Throughout Asia Pacific

Regional Languages across the globe

supported. Custom language pack can be

developed.

customers have achieved these: • 25% increase in productivity • OPE from 36% to 74% • 30% reduction in Rejection Ratio or Scrap • Future ready plant with IIOT, BigData and Analytics • Total Investment ROI in 6-8 months

Key Challenges for Manufacturing Plants

• Lack of Real Time view of Operations

• Hard to compute accurate metrics of the Operations

• No Traceability: ‘Who did it?’ ‘How?’ ‘When?’ ‘Using what?’

• Process enforcement issues leading to Quality issues

• New products and updates take longer to launch

• Over heads to manage Compliance and export Constraints

Our solutions to challenges faced by Manufacturing plants.

Industry 4.0 Platform Making Factories Smarter

Key Modules of

KPI Module • Reports / Dashboards for

• Receiving • Staging • Manufacturing • Dispatch

• Report Types • Rate of doing tasks • Time take for doing tasks • Status • OPE, OEE, TPEE • Volume • off-spec batch, Reject Batch

• Key Features • Traceability & Drill down • Zoom/Time Range • Assign Task / Leave comment • Configurable Chart Types • Configurable Dashboards • Machine Data + User Actions

Integrated Live views

• Batch Number • Date of expiry • Vendor details

KPI Example: Rejected Batch traceability

Resource

• Sensors • IoT

• Date of Manufacturing • Date of received • Certificate of Analysis (COA)

• PLC • Machine performance

Quality Rejects List Material & Batch

Execution List

Resource Utilization

Material Information

Machine Information

Click

Item

Click

Resource Utilization

Click

Material

Click

Critical Control

Parameter

Click Batch

Goods Receiving Module Users & Functions

Goo

ds re

ceiv

ing

Executed on

Handheld device

Staging Module St

agin

g

Users & Functions

Executed on

Handheld device

Manufacturing Module Pr

oduc

tion Users & Functions

Executed on

Handheld device

Dispatch Module Di

spat

ch Users & Functions

Executed on

Handheld device

- Extends & Interfaces with SAP ECC Master data in SAP synced with Vegam 4i :

• Materials Master data (MRP Controller, Purchasing Group, PPE, Hazard Info)

• Recipe BOM details

• GHS Label Information

Transactions Synced by Vegam 4i : • Purchase Order details (Used for Purchase Order Calendar in Vegam)

• Process Order Details(Used for Staging and Manufacturing Calendar)

• Delivery Order Details (Used for Delivery Calendar)

Connected to SAP

Transactions Vegam Performs in SAP

• Material Movement (MIGO, Bin-2-Bin, Put Away (Raw Material & FG), 261 RM / FG

Consumption, 101 for Booking stock FG, Post Goods issue)

Other Transactions:

• Process Order Final Completion, Time Ticket Update, Production data, Lot Number

in SAP and Extended in Vegam, Auto Batch Determination, For JIT QC Update in

SAP, Extract RM QC from SAP

Connected to SAP

- Extends & Interfaces with SAP ECC

Key Advantages of Implementing • Empower man & machine to make real time decisions based

on data

• Internet of Things Enabled and Empowered

• BigData, Predictive & Preventive actions

• Just-in-time training, Just-in-time instructions for safer and dynamic manufacturing

• Digital Standard Operating Procedures for adopting quick product launch cycles

• Integrate all aspects of a Manufacturing plant & offer a holistic view in real time

• Paper-less operations, reduced human errors, improve efficiency and enhanced transparency

Further References

Evolution of Industrialization

Industry 3.0 Industry 4.0

Industry 4.0 : The way we see it

Man or machine, taking right decision at the right time

See things as they are from wherever you are

Perform preventive and predictive actions

Architecture

Where Fits into IT landscape BI ERP Vegam 4i SCADA

More solutions from

• Large Volume Data Store

• Real time data pump from various sources into Cloud and Cloud Historian

• APIs for Third Party to access for Running Analytics and other algorithms

• Real Time Data Visualization Platform

• Supports 3D models with real time data overlay

• Supports 360* Visualization (Similar to Google StreetView)

• Built in Manufacturing Plant Specific KPI Reports with Drill Down

• Virtual Reality Walkthroughs with Live Data Overlays

• Label Design and Management Solution

• Label Data extraction from ERP / 3P DB

• Compliance Information from ERP / 3P DB

• Multiple Printers and Print Servers Supported

Module Screens

Compliance to EHS & PPE Manufacturing

Operator

1. Manufacturing operator start manufacturing

2. Logon to Handheld & select option

3. Select PO and Locate the PO Kit

4. Display phases and start phase

5. Putting raw materials in to mixer and confirm Phase

6. Sampling Labels 7. Lab Results 8. Confirm Process Order

Before confirming any phase, operator has to confirm PPE.

Step 4

Prod

uctio

n

PPE displayed & CONFIRMED on handheld device

Manufacturing Operator

Prod

uctio

n Compliance to Standard Operating Procedures

1. Manufacturing operator start manufacturing.

2. Logon to Handheld & select option.

3. Select PO and Locate the PO Kit.

4. Display phases and start phase.

5. Putting raw materials in to mixer and Confirm Phase.

6. Sampling Labels. 7. Lab Results. 8. Confirm Process Order.

If pre-weigh/staging is not done, system ask operator to do staging first for the material.

Operator confirms each phase one by one adds material as per phase instructions.

Step 5

PPE displayed & CONFIRMED on handheld device

Compliance to EHS & PPE Manufacturing

Operator

1. Manufacturing operator start manufacturing

2. Logon to Handheld & select option

3. Select PO and Locate the PO Kit

4. Display phases and start phase

5. Putting raw materials in to mixer and confirm Phase

6. Sampling Labels 7. Lab Results 8. Confirm Process Order

Before confirming any phase, operator has to confirm PPE.

Step 4

Prod

uctio

n

PPE displayed & CONFIRMED on handheld device

Manufacturing Operator

Prod

uctio

n Compliance to Standard Operating Procedures

1. Manufacturing operator start manufacturing.

2. Logon to Handheld & select option.

3. Select PO and Locate the PO Kit.

4. Display phases and start phase.

5. Putting raw materials in to mixer and Confirm Phase.

6. Sampling Labels. 7. Lab Results. 8. Confirm Process Order.

If pre-weigh/staging is not done, system ask operator to do staging first for the material.

Operator confirms each phase one by one adds material as per phase instructions.

Step 5

PPE displayed & CONFIRMED on handheld device