Manufacturing

  • Logistics and warehousing
  • Production operations management
  • Field force automation

Logistics and warehousing

The comprehensive system for warehouse management (WMS) controls warehouse processes from the moment the goods are received (logistic unit, raw material, product), during the whole time the goods are stored in a warehouse, up to the moment they are issued.

 

Basic advantages:

  • minimization of mistakes in performing logistic processes – reducing costs of providing services, better availability of goods, improving the quality of customer service,
  • integrity of materials and information flow – compliance with the GS1 system (EAN/UCC) enables tracing goods in the entire supply chain,
  • accurate representation of resources in real time – possibility of optimization and effective planning of production,
  • advanced optimization and reporting mechanisms – reducing logistic costs and stock maintained in warehouses,
  • better processing and prompt provision of services – improving the quality of logistic services, increasing competitiveness,
  • mechanism of optimization and planning picking routes – shorter time of picking,
  • service of different customers in many storage models – flexibility of operation, comprehensiveness of services.

Our WMS solutions are characterized by flexibility – they can be adapted to the needs of Customer, and can work with mobile computers operating based on automatic identification technologies, such as bar codes or RFID. The use of this technology, as an integral part of WMS systems, enables real-time data registration and processing and performance of warehouse operations at any location.

 

Application

Basic tasks performed by warehouse systems are typical logistic operations, such as receipt, issuance, or stocktaking. Apart from these functions, there are processes in certain branches that would be difficult to carry out effectively without warehouse system.

 

Manufacturing sector

  • tracing batches of products,
  • ensuring the continuity of supplies of raw materials and semi-finished products to the production line,
  • optimization of processes and use of warehouse space,
  • picking of deliveries, both as complete logistic units and unitized orders.

 

Customization

One of advantages of our solution is its flexibility and scalability. It can be adapted to the requirements of any company, regardless of branch, size or type of processes performed – raw materials warehouses, semi-finished products and finished products warehouses, organized in various forms of storage (in-line or block, on racks or directly on the floor) and keeping goods (pallets, piles, silos).

Our solutions have built-in, advanced reporting mechanisms, and enable effective storage and archiving of information about all tasks performed linked with specific logistic units. The data provided enables tracing the warehouse inventory in real time, and makes it easier for the managers to take decisions. Extended reports also enable tracing the origin of products in the entire production and logistic process.

WMS systems also offer advanced optimization methods, relating to both the use of warehouse space (optimization of storage of goods) and the performance of processes. An example of such support is optimization of routes during preparing deliveries, ABC analysis improving flows in a warehouse, controlling the flow of products according to the principle FIFO, LIFO or FEFO (First Expired First Out).

The WMS system can be used independently to manage warehouse processes, however in order to fully use its capabilities it must work with external systems used in an enterprise, e.g.:

  • ERP (Enterprise Resource Planning),
  • TMS (Transport Management System),
  • MES (Manufacturing Execution System).

This combination gives a user a comprehensive IT solution for enterprise management. The WMS systems implemented by our company are much more flexible and customizable than similar logistic modules that are part of ERP systems. As opposed to them, they are focused more on real-time management of the flow of materials than on transaction processes – the main functionality of ERP systems. The possibility of changing and developing the system along with the development of a company guarantees continuity of operation and optimization of costs of investing into IT.

Production operations management

Basic advantages:

  • production monitoring – tracing completion of orders in real time, gathering data for optimization of and accounting for production, analysis of efficiency at individual production phases, systematic quality control and maintaining the effect on qualitative parameters of manufactured product,
  • production supply – reducing stoppages due to shortage of materials (raw materials or semi-finished products), improving quality by supplying appropriate materials for production,
  • track & trace – possibility of tracing goods in the entire logistic chain, compliance with the GS1 system (EAN/UCC), organizing the system of marking logistic units.

In order to fulfill three basic tasks, which need to be accomplished for an enterprise to achieve success, it is necessary to appropriately manage production processes. These tasks include:

  • ensuring quality in production processes – ensures that Customer will receive a product of expected, guaranteed quality,
  • effective management of production orders – ensures that a product will be manufactured and delivered on time,
  • control of production costs – enables cost control and optimization.

Effective fulfillment of these tasks is impossible without precise tracing and controlling of the stages of production processes. This requires information about production process which is detailed enough for the system of controlling production stages. Such information says:

  • who (worker/shift/team) manufactured,
  • where (plant/post/section),
  • when (date, time),
  • by means of what (machines, tools),
  • from what (raw materials, semi-finished products),
  • what (product/semi-finished product),
  • how (processing),
  • time scale.

A lot of such data is often gathered in paper form (operation card, shop guides, etc.). Entering it into the system carries the risk of errors occurring during this process, and consumes workers’ time. In certain branches of production, the amount of data that should be registered is so huge that it is virtually impossible to register it manually. The question arises whether it is possible to quickly and reliably register a huge amount of data, to combine it into a coherent whole, and to enable further processing of this data in order to manage production, control quality, or conduct analyses. Is it possible to use this data in logistic areas to ensure proper cooperation of raw material warehouses (ensuring continuity of supplies to production line), or finished product warehouses (production planning, optimization of logistic costs) with production?

 

Application

Production monitoring:

  • automatic, semi-automatic or manual registration of events at the production,
  • registration and visualization of production order status,
  • registration of production stages,
  • gathering data from the course of production process,
  • reporting basic indicators (worktime, downtime, progress of order fulfillment) and efficiency.

Production supply:

  • ensuring continuity of supplies of materials to production line,
  • visualization of an order directly in a warehouse,
  • generating documents concerning issuance of goods and linking them with orders,
  • monitoring the progress of order fulfillment.

Processing warehouse documents

  • linking warehouse operations with production orders.

Track & Trace

  • forming logistic units (defining pallet composition),
  • manual and automatic printing of logistic labels,
  • reporting the origin of logistic unit.

 

Customization

Our solutions are designed for any production company, regardless of branch in which it operates. They can be quickly adapted to the needs of Customer and implemented in stages in order to minimize the effect on current processes carried out in an enterprise.

The system for production monitoring, responsible for completeness of the data gathered, can enforce entering certain information at a given stage of production process, and make the actual functioning of production system conditional on dynamic data gathered in real time. It can be deeply integrated with industrial equipment systems, with two-way information communication. On the other hand, the system for production tracing is integrated with systems of ERP class (Enterprise Resource Planning), MRP/MRP II (Material requirements / Manufacturing Resource Planning), or WMS (Warehouse Management System). Its functionality allows to use modern technologies (e.g. automatic identification) to register and supervise processes in an enterprise, and consequently to extend the functionality of management systems.

Field force automation

Basic benefits:

  • immediate access to information about the tasks charged,
  • control of task accomplishment in real time,
  • shortening time between task accomplishment and invoice issue and payment for the service,
  • eliminating errors (e.g. wrong part) through the use of barcode or RFID technology,
  • reduction of the amount of paper documents,
  • possibility of easy creation of statistics and analyses,
  • full integration with the IT system of the company.

The task of Field Services systems is efficient and effective management of the work of service centre employees or repair crews performing tasks in the field. The information about the status of tasks currently performed, received online by the central system, and the possibility to immediately send new orders to mobile terminals create the basis of an effective management, oriented to meeting Customers’ expectations at lower costs and higher efficiency. Field Services systems allow dynamic management of time, equipment, spare parts, as well as employees’ competences. Further the system user can indicate other areas which the solution should support.

The solution of IBCS Poland has application in each company with a network of field employees who perform inspection, repair and maintenance works on a scattered area.

The basic element of the system is controller application. It allows to control field employees in real time and to plan tasks/orders for them. A mobile application, installed on mobile computers, constitutes an element of communication with an employee. Its main task is communicating the tasks to an employee and registering the events connected with these orders carried out. Optimized synchronization of data with the central server through GPRS/EDGE enabled control of the status of tasks in real time, which makes the planning stage significantly easier.

The system is based on a ready and proved platform, which can be set up each time according to Customer’s needs and integrated with any IT system. Such approach ensures reliability and guarantees full satisfaction of Customer needs.

 

Applications

  • planning tasks based on the availability of resources (working time, competence, tools, etc.),
  • charging mobile employees with tasks and tracing the status of their accomplishment (service centre employees, maintenance persons, inspectors, auditors, etc.),
  • generating documents at Customer (acceptance protocol, invoice),
  • information about availability of spare parts,
  • photographic documentation of events,
  • recording working time of service centre employees, statistics.

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