Metal and Discrete Manufacturing Sector

MES for discrete manufacturing and the metal sector

The profitability of a discrete order depends on every machine minute and every operation being properly allocated.

QPlant brings visibility to discrete manufacturing: real order progress, time capture by operation, OEE with stoppage cause, digital process guide and integrated CMMS. For plants where every order matters and data has to arrive when it is needed.

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METAL AND DISCRETE MANUFACTURING SECTOR

Metal and Discrete Manufacturing

In discrete manufacturing the margin is in the details: in the actual times of each operation, in knowing when a machine stops and why, and in seeing the real progress of each order without asking. When that data does not exist, decisions are made late and the real cost per order is not reliable.

QPlant brings visibility to the shop floor with time capture by operation, OEE with stoppage cause and integrated CMMS, connecting with your ERP and control systems for seamless digitalization.

The challenges of Metal and discrete manufacturing

In discrete manufacturing, the margin is in the details: in the actual times of each operation, in knowing when a machine stops and why, in having visibility of the real progress of each order without having to ask. When that data does not exist, decisions are made late or with imprecise information — and the real cost per order is not easy to calculate.

Visibility of order progress

Visibility of order progress

  • Web shop floor terminal to declare production and statuses
  • Times and statuses by operation
  • Progress of each order in real time
  • No calls or searching through spreadsheets
  • Visibility across different resources
Allocation of times and real costs

Allocation of times and real costs

  • Time capture from terminal, PLC or sensor
  • Allocation recorded automatically
  • Calculable real cost per order
  • Profitability by reference, customer or machine
  • Reliable data to decide
Standardization across shifts

Standardization across shifts

  • Digital process guide with instructions and parameters
  • Start-up checks and validations by operation
  • Same instructions for all shifts
  • Shift changes without risk to quality
  • Reproducible operations
Stoppage analysis and OEE

Stoppage analysis and OEE

  • Stoppage logging with configured cause
  • Automatic OEE: availability, performance and quality by resource
  • Pareto charts of stoppage cause
  • Identification of where it makes sense to act
  • Losses attributable to real causes
Maintenance connected to production

Maintenance connected to production

  • CMMS integrated with production
  • Logged stoppages feed the maintenance history
  • Preventive maintenance adjusted to real usage
  • Anticipation of critical interventions
  • Less reactive maintenance
BENEFITS

What your plant gains

Every challenge solved with QPlant translates into a concrete, measurable improvement in your operation.

Reto: Little visibility of real progress · Solución: Shop floor terminal by operation

You know exactly where each order stands, without having to call or search through spreadsheets.

Reto: Manual time allocation · Solución: Time capture by terminal or PLC

The real cost of each order can be calculated. Profitability by reference, customer or machine is visible.

Reto: Poorly standardized instructions · Solución: Digital guide by order or operation

Shift changes are no longer a risk to process quality. The instructions are the same for everyone.

Reto: Stoppages with no recorded cause · Solución: Stoppage logging and OEE by resource

The cause Pareto charts show which stoppages are most frequent or longest, and where it makes the most sense to act.

Reto: Reactive maintenance · Solución: CMMS integrated with production

Maintenance stops being reactive because the history makes it possible to anticipate and plan critical interventions.

QPLANT SUITE

Priority modules for Metal and discrete manufacturing

The QPlant modules that add the most value in this sector. They are implemented together or in phases.

PRODUCTION

QPlant Production

Captures actual execution, calculates OEE and records production, rejects, waste and stoppages.

MAINTENANCE

QPlant Maintenance

CMMS connected to production: work orders, preventive, predictive and KPIs.

QUALITY

QPlant Quality

Controls, inspections, SPC and non-conformities integrated into the process, with evidence for auditing.

WAREHOUSE

QPlant Warehouse

Locations, quality statuses, FEFO/FIFO, picking and stock in real time.

ANALYTIC

QPlant Analytics

Dashboards for OEE, quality, waste and performance, with loss analysis and AI.

PLANNER

QPlant Planner

Finite-capacity planning with scenario simulation and changeover optimization.

TRACEABILITY

QPlant Traceability

Batch-to-batch traceability backwards and forwards, ready for audit and recall.

TIME ATTENDANCE

QPlant Time Attendance

Presence, shifts, access control and time allocation, connected to shop floor operations.

Solutions

Solutions and products for Discrete Manufacturing

TAI offers a suite of integrated products under the MOM/MES QPlant platform, designed to address the challenges of discrete manufacturing.

Discrete Manufacturing References

Companies in the cosmetics sector that have trusted our solutions.

Reseñas

Lo que dicen nuestros clientes

Empresas de distintos sectores han confiado en nosotros para resolver sus desafíos. Descubre cómo impactamos positivamente sus resultados.