MES Software and Digital Solutions
Smart Factory in a Few Steps
Our Industry 4.0/5.0 Solutions
Smart factory in a few steps
MES solutions represent a connection between the IT world and automation processes. They offer solutions for the optimization of operational production processes and, they contribute to increasing efficiency in your company. The full traceability of quality and production data is guaranteed - which means a competitive advantage for your company.
Over many years, the MES software series Plant Historian has been applied in international industrial enterprises in different countries in Europe, Asia and South America. Best practice was the key to continuous development and improvement of Plant Historian. Plant Historian is an ‚out of the box‘ solution for long-term archiving and the evaluation of alarms and events, process data archiving and analysis, laboratory and machine data acquisition, digital shift book and energy management according to ISO 50001, OEE and production data.
The use of Plant Historian brings higher transparency, data availability and plant security to your company.
safe - transparent – central
Plant Historian 5
Modules
Plant Historian 5 AM
Systematic Alarm Management for more Plant Security and Transparency
The MES software Plant Historian 5 AM – Alarm Management – is a company-wide applicable, central solution for long-term message archiving and analysis for your process control system.
Comprehensive analysis functions support structured procedures for alarm reduction and plant optimization. Systematic alarm management means a relief for the plant staff and stands for plant safety. Optimization approaches can be identified early and continuously and can be realized sustainably.
Alarm management and Alarm rationalization (rationalization of alarms, configuration of alarm parameters and prioritization) are essential for an increased security of plant and personnel.
Benefits
- Increased plant security and availability
- Identification of bad operations
- Support for alarm reduction
Core Features
- A&E evaluation of frequency and distribution, e.g. according to calendar weeks
- KPI reporting according to ISA 18.2, NAMUR NA102 and EEMUA 191
- Direct alarm forwarding via SMS, E-mail, phone
Plant Historian 5 AR
Alarm Rationalization for increased Plant Security
Alarm rationalization describes the comparison of alarms with the respective alarm concept as well as the determination and documentation of the alarm reasons.
Rationalization of alarms also comprehends the configuration of alarm parameters.
Another important feature is the recording of possible consequences and corrective actions for occurring alarms and their prioritization.
The prioritization of alarms is normally based on the effects of ignoring alarms (damage to people, environment and machine) and the remaining reaction time for the operator in an alarm situation.
Benefits
- Increased plant security through conscious alarm prioritization
- Support for alarm reduction
- Alarm prioritization starts the MoC process (Management of Change)
Core Features
- Intuitive alarm classification
- Validation of the rationalization measures (comparison of planned and actual data)
- Basic/initial situation for alarm rationalization directly from the process control technology
Plant Historian 5 PDA
Process Data Archiving: Recording, Analysis and Archiving of Process Data
The MES software Plant Historian 5 PDA – Process Data Archiving – is a central system for the recording, analysis and archiving of process data.
Plant operators benefit from the complete, company-wide availability of process data and comprehensive and intuitive analysis functions.
Benefits
- Quality control and process optimization
- Optimization of internal and external communication
- Transparent visualization of the plant status
Core Features
- Numerous analysis tools and display options
- Trend display with visualization of the associated process control system messages and direct display of limit value violations
Plant Historian 5 RDA
Remote Data Access
The MES software Plant Historian 5 RDA – Remote Data Access – is a central system for the recording and control of selected data points from remote equipment / locations.
Remote data access is an instrument enabling plant engineers to use personnel and materials effectively and save time and costs, particularly in warranty periods.
Benefits
- Security as a result of early error detection
- Regular control of the plant status
- Remote ad hoc analysis of industrial plants
Core-Features
- Global remote access to equipment and plants
- Fault reporting from remote plants
- Archiving and analysis of remote plants, machines and equipment
Plant Historian 5 BDE
Paperless Acquisition of Operational Data for more effective Production Processes
The MES software Plant Historian 5 BDE - Operational Data Acquisition - is a system for the central recording, visualization, documentation and evaluation of operational data.
Effective production processes require effective operational data management. Users of the MES software Plant Historian BDE benefit from secure digital data acquisition and fast reaction options in cases of limit value violations.
The input mask can be individually configured by the user, without any programming effort. Centrally recorded data like batch and quality data, quantities, running times and downtimes in correlation with possible reasons can be output as shift or production reports or in any other kind of report.
Benefits
- Central paperless acquisition of operational data
- Support for internal and external audits
- Escalation in cases of limit value violation and indication of procedural instructions
Core Features
- Manual or automated acquisition of manual values
- Manual or automatic reporting
- Numerous analysis tools and display options
Plant Historian 5 RM
Reporting
the MES software Plant Historian 5 RM - Reporting Module - is a central system for the automated creation of production-relevant reports such as shift, audit and batch reports or loading documents.
The clear reports support you both in your internal processes and in your cooperation with your customers and business partners.
Plant Historian RM offers a flexible reporting system that can be completely adapted to your needs. Recurring reports like shift reports or daily evaluations can be automatically forwarded to predefined recipients at regular intervals.
Benefits
- The right information to the right recipients at the right time
- Automatic creation and forwarding of KPI and OEE reports
- Use of existing Excel templates
Core Features
- Output of reports as PDF or in Excel
- Automated forwarding to predefined recipients
- Any kind of report type: shift, daily, monthly etc.
Plant Historian EM
Energy Controlling and Energy Monitoring according to ISO 50001
The MES software Plant Historian 5 EM - Energy Management - is an energy monitoring and controlling system for the complete recording of energy flows and for the identification of energy efficiency potentials and their realization.
Users benefit from data transparency, detailed display options and the possibility to control and optimize energy costs.
The MES solution Plant Historian 5 EM - Energy Management - offers energy montoring and controlling according to DIN EN ISO 50001.
Benefits
- Transparency of energy data and ressources used
- Automated reporting of energy data
- Reduction of energy costs
Core Features
- Evaluation of consumptions and cost centers
- Visual display options for cunsumptions, peak loads etc.
- Validation and alarming of balancing groups
Plant Historian 5 MDE/MDA
Machine Data Acquisition
The MES software Plant Historian 5 MDE/MDA - Machine Data Acquisition - is a system for the central acquisition, control and evaluation of machine data. Plant Historian MDE/MDS - Machine Data Acquisition - offers the complete acquisition and recording of machine data.
Information is presented transparently. An effective monitoring and evaluation of machine data and processes is guaranteed.
Recorded data are the basis for the identification of optimization potentials and the continuous optimization of processes.
Benefits
- Transparent presentation of the machine status
- Immediate detection of deviations
- Increase in machine availability
Core Features
- Acquisition of technical operational data
- Determination of key figures and benchmarking
- Transparent machine monitoring and analysis
Plant Historian 5 OEE
Overall Equipment Effectiveness
The MES software Plant Historian 5 OEE - Overall Equipment Effectiveness - enables the plant operator to record, analyze and document unplanned losses and downtimes (short-term lack of staff, system malfunction etc.). The overall equipment effectiveness of a system is a product of the factors
- availability
- performance
- quality
Benefits
- Transparent presentation of production data
- Immediate detection of deviations
- Incresed availability as a result of direct information forwarding of the machine/plant status
Core-Features
- Recording of technical operational data
- Determination of key figures and benchmarking (overall equipment effectiveness)
- Transparent machine monitoring and analysis
Plant Historian 5 HMI
Visualization of Production / Manufacturing Processes
The module Plant Historian 5 HMI - Visualization - provides the visualization per drag & drop of different production key figures on one surface:
- Machine data (MDE/MDA)
- Production and manufacturing units
- Alarms and events
- OEE key figures
- Actual process values
Benefits
- Abstract visualization of plant status and consolidate information
- Networked presentation of machine and production units
- Transparency due to information networking (Big Data)
Core Features
- Flexible dashboarding per drag & drop
- Personalized layouts
- Presentation of alarms & events, process or machine data, OEE key figures etc. on one surface
SHIFTGURU
Digital Shift Book
The digital shift book SHIFTGURU is a central system providing the digital acquisition and documentation of shift events.
Instructions, shift information and events are recorded and archived uniformly across the whole company. Customer-specific checklists and forms can also be integrated into the shift book.
Data are recorded completely and in compliance with the regulations along the whole production chain.
NEW - Our digital shift book solution is also available as web version!
Benefits
- Reduced data acquisition, report and research effort
- Statistic evaluation options
- Simple handling
Core Features
- Documentation and recording of shift events
- Individual generation of shift schedules
- Audit compliance
Plant Historian 5 PM
Predictive Maintenance
Plant Historian 5 PM - Predictive Maintenance - provides the possibility of a preventive reaction concerning machine disturbances and standstills. The tool reduces downtimes, saves operational ressources and decreases maintenance costs.
Predictive Maintenance provides permanent equipment (assets) monitoring – by using sensors measuring vibration, temperature humidity etc.
Predictive Maintenance allows action instead of reaction.
Benefits
- Reduction of downtimes
- Predictive maintenance measures
- Planning predictability in production
Core Features
- Control of all maintenance-relevant data
- Recognition of maintenance tendencies as a result of accumulation of data (Big Data)
- Recording of maintenance measures
Plant Historian 5 PTT
Process Tracking & Tracing
RFID helps to document, which material is intended for which production unit (furnace, casting machine, packaging units etc.) - thus avoiding the supply of any material to the wrong production unit.
The material flows are fast, visible and traceable at any time.
The result is a more efficient logistic process with increased quality and less costs due to error avoidance.
Benefits
- Traceability of recorded process data
- Error avoidance in planning, control and documentation processes of the material flow
- The right material to the right production unit
Core Features
- Coordination and optimal use of ressources
- Linking of transport systems with plant automation
- Intuitive user surface
Plant Historian 5 DCL
Digital Checklists - simple, reliable and secure
Securitiy and work relief are the characterisitics of a scanner-based data acquisition and control system.
The complete cylic data acquisition and control are guaranteed. Defective parts are documented and immediately reported to the maintenance department as "task to be completed". This will create a workflow that sustainably optimizes communication among quality management, maintenance and other departments.
Digital data acquisition facilitates research for certain results, e.g. when keeping a glass register according to ISO 22 000.
A practical example (only in German): iScan Glaslisten-Management - Digitale Checklisten in der Lebensmittelindustrie
Benefits
- All documents / lists are digitized and available at any time
- Data acquisition is reduced to necessary input fields
- Plausibility check of recorded data
- Escalation logic in cases of non-acquisition of data or limit value violation
Core Features
- Data acquisition is possible on site at the plant, even without any connection to the network, but with later synchronization
- Data acquisition via scanner, tablet, smartphone or Windows Client
- Platform independence (Mac, IOS, Windows, Android etc.)