Two production shop floors in one environment

A printing industry with more than 30 employees sets foot in Industry 4.0 with Epoptia MES.

Complexity made simple

An intricate production process that took place in 2 discrete areas is now handled and managed by Epoptia in a single environment.

Said printing industry’s main and noteworthy feature is innovation and that is why its preexisting costing and computerization system was able to offer flexibility and traceability but to some extent. Nonetheless, with Epoptia they are in a position where they can achieve utter control and traceability throughout all stages of production. This transpires while providing better employee and machinery management and actual performance measurement at the same time. Hence, the company can introduce yet another outstanding advancement, since it has always been on the forefront of innovation and its primary mission is to keep on investing in it and inspiring others.

CASE STUDY

Productivity & Reporting on hands

CHALLENGE

Integration into the computerization and costing system

The preexisting system was not designed to work in tandem with other systems and for that, it required Reverse Engineering, something that was painful and required a considerable amount of investing. What is more, some major radical changes to the system had to be done manually and the re-engineered system faced the likelihood of not being as maintainable as it should.

Integration so as to maintain existing functions

In an already established user interface, it is almost prohibited to tamper with things and especially procedures. Additionally, it requires that those responsible perform an awfully close analysis and recording of each procedure.

Reporting

The preexisting system indicated a fixed production time. However, this was not attainable throughout all workstations and as a result, the intermediate production stages were entirely beyond the administration’s control. At this point, the main objective is to boost employees’ and machinery’s productivity.

Downtimes & Alarms

The administration, being innovative and wanting to revamp their production’s image, aspired to identify idle times but also to get a better picture of their issues in order to optimize them and their procedures as well.

SOLUTION

Industrial Background & Software development experience

In the interest of fully integrating the functions of the preexisting system, extensive research and demanding Reverse Engineering was implemented in order to gather the necessary information and adapt Epoptia to the way the existing system operates. The persistence of Epoptia engineers, the industrial background, and the experience in software development played a crucial part in the project’s realization and its favorable outcome.

Employees seeing the data that where on paper, keeping the same procedures

Epoptia team worked closely with the factory’s innovative managers to record all existing procedures and integrate them into the software. At this point, following the existing processes that the employees were already familiar with was of the utmost importance. Employees adapted to Epoptia straight away as a result of it being extremely user friendly and because of the fact that what they were looking at now was all that they previously used to see on paper.

Productivity Reports

With Epoptia’s simple interaction with employees, there is real-time traceability and information on employee productivity and efficiency is easily gathered as well. As employees become more and more acquainted with Epoptia and the better they interact with it, machine efficiency will increase ensuring an additional improvement in productivity.

Alarm & Notification System

By using the Epoptia alarm system, those in charge now have knowledge of how much time is spent on each of the issues that have surfaced. They can also identify how often these issues occur and what was the cause of their emergence. Hence, they can pinpoint their exact ‘place of suffering’ and take precautionary measures for even greater efficiency. At the same time, idle times are tagged, together with their cause and frequency. In this way, they can optimize their procedures.

Next Steps - Getting Deeper in IoT & AI-Driven Scheduling

Innovation is a key feature of the aforementioned printing industry; ergo, it is no surprise that the next steps towards this direction are already in place. Coming next is the connection of all machines with the Epoptia platform, while there is a profound interest for the upcoming Epoptia module. That module will offer possibilities for forecasting and indicating better Planning & Scheduling, through specialized Machine Learning & Artificial Intelligence algorithms.

Digital transformation made easy

Enter Industry 4.0 era.

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