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InfoCarrier1™
Customer: Provis GmbH & Co. KG
Business Case: Provis, a leading supplier of Manufacturing Execution Systems (MES) required a
low-cost IT solutions partner to help customize its flagship product, InfoCarrier1, to meet the needs
of individual customers.
Solution:
Background of InfoCarrier1
A production management system with process-oriented operation is referred to as a Manufacturing
Execution System (MES). Compared with other similarly operative ERP (Enterprise Resource Planning)
systems, it is excellent for administration due to its direct connection to automation and enables
the production to be controlled in real-time. This includes classic data acquisition and preparation
such as the acquisition of operating data, machine data and personnel data, as well as any other
processes that have a real-time effect on the manufacturing/production process.
The term MES relates to an all-inclusive system that covers the area between the ERP at company
management level and the actual manufacturing/production process at production or automation level.
MES products are available both as an all-inclusive package and as individual components.
One of the advantages of InfoCarrier1 is that all of the components originate from the same source,
and are integrate seamlessly. This has been achieved through the use of a single database, single
menu navigation and a central configuration module.
Sitex Involvement with InfoCarrier1
Sitex developers work directly with the developers at Provis to customize and implement features to
meet customer requirements. During this partnership, Sitex developers have also been tasked with
rewriting significant parts of the software code base to improve efficiency, as well as migrating
the software to newer versions of the development tools, used to build the software.
Alert Message Administration
Sitex developed an "Alert Message Administration" component for InfoCarrier1.
This component consists of the following modules:
- Alert Type Administration
Defines the types of alerts, translation of messages and further processing.
Allows viewing and – if the user has sufficient privileges – to edit messages, delete them, performing manual forwarding, printing etc.
User defined filters allowing users to select alerts according to different criteria.
Allows grouping of certain alert types for defining the further processing of alerts
Allows defining groups or users who should receive alerts at certain times.
Background processing of alerts, e.g. e-mailing, sending SMS, transfer to other systems etc.
Reporting and Evaluation Manager for InfoCarrier1
Sitex developed a "Reporting and Evaluation Manager" component for InfoCarrier 1. This component provides the following functionality:
- Quick and easy navigation between reports.
- Extensive end-user interface design features.
- Convenient report filtering capabilities.
- Multiple language support.
- Automatic verification of customized reports against database modifications.
- Support for multiple report handling options, including fax, e-mail, export to Excel, and export to Web.
Statistical Process Control
Sitex developed an "Alert Message Statistical Process Control (SPC)" component for InfoCarrier1. This new
component provides control over the processing and the display of alert messages that may be raised to indicate
problems in the manufacturing process being controlled. This module was integrated into InfoCarrier 1 by Sitex, so
that alert messages can be seen along with measuring data, set points and production run information. This component
required Sitex to develop the following modules:
- Visual Components Library (VCL), to define the rules for SPC processing in different parts of the production system.
- A new data form to allow the user to define alerts.
- A background execution task to check for SPC rule violations.
Warehouse Management
Sitex developed a "Warehouse Management" component for InfoCarrier1. This component was developed as part
of the process control system for large-scale chemical plants. The component includes the following features:
- A user-friendly graphical interface for planning and management of multi-level storage.
- Storage optimization by surface elements.
- Batch management.
- Continual monitoring of stock.
The functions of InfoCarrier1
InfoCarrier1 is an MES that has been specially developed for continuous production processes. The software is
built upon a high-capacity Oracle database, the "Plant Data Repository". The wealth of information
subsequently gained enables a large number of functions serving data integration and analysis:
- Monitoring and optimization of production processes, fault analysis, performance comparisons, aging analysis.
- Quality Management of raw materials, production processes, semi-finished and finished goods.
- Monitoring of product flows, calculation of mass balances, traceability.
- Warehouse logistics for raw materials, additives, intermediate products and finished goods.
- Packaging of bulk goods in single batches, batch sampling, and quality determination.
- Shipping of bulk goods or packed goods with automatic quality certification, by truck or freight train.
- Back-posting of produced amounts, filled batches, product changes, quantity corrections and dispatched goods in the ERP system.
- Emission monitoring, CO2 trade.
- Determination of Key Performance Indicators:
- Consumption of raw materials, additives and energy in relation to the production of main and
subsidiary products (remote heating, electricity)
- Evaluations regarding system conditions, downtimes, product changes
- Quality and yield with respect to setting conditions, system types, raw material qualities and equipment
- Breakdown frequencies, performance of equipment
- Raw materials and product stocks, exact to the minute
- Handled goods quantities
The InfoCarrier1 Modules
InfoCarrier1 performs the functions mentioned above using a system with function modules.
- Raw Materials Management
- Production
- Configuration of the production lines
- Production planning
- Analysis of process and quality data
- Statistical Process Control (SPC)
- Quality Management
- Sample Administration / LIMS
- Product properties and specifications
- Quality certificates
- Finished Product Management
- Receptacle Management
- Batch Management
- Packaging and RFID labeling
- Warehouse
- Shipping
- Truck and freight-train weighing
- Inter-plant shipments
- Silo switching
- Reporting
- Data Analysis Reports
- Reporting Manager
- Traceability Reports
- Interfaces
- Connection to Process control systems and PLC
- ERP interface (e.g. SAP)
- Programmable interfaces for laboratory equipment
- Basic functions
- User and User-rights Administration
- Multilingual User Interface
- Alarm system
Tools and technologies: C++, C#, CodeGear 2005, Oracle
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