For WEBA, we developed innovative utilities to streamline and automate business processes. Both the processes occurring directly on the production floor and in office conditions.
From the beginning, our collaboration was innovative, combining software with dedicated devices and industrial robots.
The software of the devices placed in production stations, implemented in the form of recorders reading data from the card, enables monitoring of the progress in the completion of individual tasks and the work time of the operators.
With the panel, the employees obtain insight into the completion status and review the numbers of pieces ordered and completed under the task. The assigned list of tasks shows their numbers and product names. Another essential function is access to technical documentation and comments on the task.
The system enables online access to the list of all current and completed tasks with full information on task specifics: index number and product name, completion time. The progress to completion and completion time are monitored on an ongoing basis and according to the status, messages are displayed with information whether the given task is completed in a timely manner, in advance, or with delay. In a single glance, you can also check their placement in stations.
Scanners, card readers, station operating panels, or printers are peripheral devices, without which the production process cannot be supported in a comprehensive manner. Their software and integration were an inherent component of work on production process automation.
Each of the millions of components produced is labeled with automatically generated data related to the order and manufacturer, including the name and serial number, batch, barcode, and more. The appropriate number of labels is printed either as a result of an automated signal sent by a robot or by scanning the barcode placed on the order.
In managing the information flow in the production company, the essentials are automation and access control, as well as employee identification and work time recording, which were implemented through the integration of RFID identification cards. The employee is supported in an automated manner, without requiring for example signing and filing paper documentation.
The primary objective in the development and implementation of the solutions for WEBA, from the earliest stage of collaboration, was to enable effective products management: from production planning, assignment and prioritisation of tasks, to the completion of the production process, while monitoring processes, saving and using historical data for future optimisation.
Presentation of the current orders in a useful dashboard form enables a complete view and optimum management of the production while maximising the production potential and increasing the performance.
For effective production planning and task assignment, we implemented modules responsible for managing human resources and employee schedules in one or more shifts. Based on the created schedules and work recording systems, presence reports are generated and ready for further processing in accounting.
Using the production calendar, considering for example the calculations of the time necessary to complete the task and the resources available, the capacity is determined. On its basis, daily tasks are assigned in a simple and optimum manner.
In the design of the production management system for WEBA, we had to consider many aspects of operation in the production industry. Our priority was to deliver a tool that would be intuitive to use despite its complexity. The friendly graphical form of presentation of the data, plans, reports and schedules streamlines business processes and the simple interface of terminals facilitates the use.
Thanks to computerisation of documentation processes, which was an inherent assumption in our work for WEBA, we can eliminate errors and save time. Thanks to a documentation generator and its integration with a configurator, it takes a few minutes to perform activities, such as pricing and offer preparation. Apart from automatic generation of the offer, technical or tender documentation, the system allows the user to sign documents digitally and send them automatically, as well as manage certificates and templates validity.
In line with the idea of production and sales automation, we have created a system which allows for combining software and devices which make up an industrial automation system. Production stations are operated by robots which send messages concerning the status of order execution, current progress in implementation and the condition of the robot itself, thanks to which comprehensive information is available and visible at a glance even from a distance for employees in the production hall.
To complete this multi-component system, we adopted a series of solutions, of which the combination could support both the sales support and production processes. We used for example React PHP - an asynchronous PHP library that was perfect for high-performance network servers and clients that support hundreds or thousands of simultaneous connections. Significant solutions also involved communication with robots at the socket level.
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