The Benefits of Real Time Collaboration Via the Web
Datasweep delivers the only Web-centric real-time collaborative manufacturing solution that enables manufacturers to monitor manufacturing processes and key production metrics, such as work in process and quality, to improve product lifecycle management and reduce costs. The benefits of a Datasweep solution include:
- Improved product quality
- More production output without additional resources
- Easier changeover and mix management
- Better process visibility
- Ability to track and manage products from NPI, to manufacturing and repair
- Reduction of inventory
- Better decision making using integrated reporting and analysis tools throughout manufacturing and post-manufacturing
- Fast and significant ROI on Datasweep and other enterprise investments.
ZF Meritor, a leading manufacturer of heavy-duty truck transmissions and clutches, selected Datasweep as its partner to supply the critical manufacturing software infrastructure that is a key component of quality assurance for assembly of their new FreedomLine™ transmissions. ZF Meritor will use Datasweep Advantage to monitor and track manufacturing quality and collect production data by leveraging the Web for real-time visibility into and control of their manufacturing processes.
2. Ability or need to customize software solution based on application? Does Automotive industry need specific requirements when it comes to factory floor automation where your product will need modifications?
The automotive industry likely has the highest level of automation out of all industries. Beginning with plant floor devices, it has methodically advanced the offerings of both the software and hardware suppliers to provide systems that are vigorous, redundant/safeguarded, foolproof, with "state of the art" in capabilities. The earliest implementations of "Computers in Manufacturing" were done at the behest of the Big Three.
Automotive was the first industry that created the production line-rolling out hundreds of the same products (Ford said you can have any color you want as long as it is black) and they became proficient at standardizing and streamlining manufacturing to shave time off each unit, for cycle time and downtime were the two items that cost the manufacturers money-they weren't making cars. Systems that provided the automaker advanced warning of downtime (such as maintenance management systems) or software that managed the process to minimize exceptions (alarms and events) became critical to the manufacturer.
Software for the automotive market has traditionally been customized to reflect the specific manufacturing processes undergone, and the terminology used by the plant operators and management. Datasweep built Advantage with the ability to customize both the user interface (with the ability to present screens based on security privileges, or job function/title, or operations) and the product itself to reflect the actual conditions of the floor and products it is tracking. This is done both through product configuration and through a scripting environment.
The high level of automation present in an automotive environment means that people may not always be the sole data collection mechanism-data feeds may come from bar code devices or other automated collection equipment, or can come from the process control equipment-PLC's (programmable logic controllers) or from the different software products that may be monitoring and controlling a particular manufacturing work cell. As the primary "overseer" of the process, Advantage's strong capabilities in real-time data collection and presentation are ideal for automotive's requirements for immediate process feedback, control, monitoring alarm/event management and corrective action. Extending the capabilities through a robust quality system, closed loop process control is now enabled by constructing an effective NCR/CAR process, using the real-time quality and performance data tracked within Advantage, to ensure corrective actions have been taken and monitored.
3. capability with other data collection systems currently being used? relationship with ERP, wireless, compliance labeling, etc.
As Datasweep is designed for use under the normal operations of a plant floor, automatic data collection is a necessity. Advantage regularly interfaces to automatic data collection and process control devices such as barcode, RFI, and PLC's (programmable logic controllers). From an enterprise software standpoint, Advantage has been integrated with ERP packages (where the Bill of Material may reside and need to be executed upon); Product Data Management packages, (where the layouts and product designs are created); or scheduling packages (where customer orders are prioritized and scheduled). All are fed data from the actual process, be it the consumption of inventory, bottlenecks occurring in the process that could affect delivery dates, or product design changes/engineering change orders that must be executed and validated; Advantage is the software product responsible for capturing all manufacturing data, maintaining the build history of each unit in production, and transferring all real time and historical data to any system that requires updates.
Being web based allows all parties to proactively view the real time data collected and resultant reports that aggregate and display manufacturing results. Additionally, the real-time data collected is compatible with and actually helps improve the performance of other enterprise applications, e.g., APS- providing actual yield and cycle time data to improve plans; ERP, providing details on actual inventory consumption for more accurate purchasing, supplier score cards to better manage their supply chain, and manufacturing cycle time, enabling more effective customer ship and delivery information.
4. functionality of software?
Advantage was designed to leverage the power of the web, allowing all supply chain partners access to build and repair information through a common browser. This "collaboration" is the cornerstone of Advantage's success. The standard functionality of a Manufacturing Execution System-quality, work in process tracking, inventory management, maintenance management, document control, etc. are enhanced by Advantage's robust data aggregation, warehousing and reporting-again, available through a browser, with customized views. Coupled with quality, integrated analysis and reporting, Advantage provides closed loop correlation of manufacturing to field performance & proactive correction.
5. Are there others in the same marketplace? (opinion) Large growth in your arena? Sales % increase from last year to this year?
There are others in our space from a MES perspective-traditionally, these have been smaller firms such as RWT and iBaseT, or broader-based "controls" software vendors such as Wonderware, Rockwell Software, and GE's Cimplicity products. These control products cover a wider base than just MES, adding in plant floor visualization, process historians, and automation equipment interface/data acquisition.
Datasweep's position for the automotive market is to extend its collaboration, visibility, and supply chain management capabilities onto the shop floor, which differentiates our offering from these existing vendors. We see growth in this area as the automotive suppliers are going to a BTO model; the need for quality and supplier management is critical; and with cost savings measures, inventory reduction and yield increases are necessary to maintain competitiveness.
As automotive manufacturers continue to invest in manufacturing and plant floor systems, Datasweep sees the automotive market as a natural progression from the high tech industries that we have already served with success-telecom, optical, medical devices. As such, we see significant new growth both from direct sales and through strategic partnerships as with GE Fanuc, who will be representing us in the OEM space.
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