Vegam Solutions
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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
Industry 3.0 Industry 4.0
Industry 4.0 Platform Making Factories Smarter
• Eliminates picking & consumption of wrong batch or materials.
• Eliminates human errors while manufacturing. Critical for semi automated operations.
• Records the actual operations as is. Critical for traceability.
• Manual operations and machine operations logged synchronously.
• Predictive & preventive inputs for production to enhance quality.
• No additional data entry or process tasks.
Key advantages of implementing
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
- 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, Putaway (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
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
Further references
Evolution of Industrialization
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
Logos, TM and copyrights belong to respective parties.
Where Fits into IT landscape BI ERP Vegam 4i SCADA
More solutions
• 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
Modules 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
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