Cutting-Edge Manufacturing Execution Systems

• Job Scheduler
• Job Summary
• Job Shift Summary 
• OEE Dashboard
• Production Summary
• Production Events
• Reject/Scrap
• Downtime
• Email, text and voice alerts
• Production Dashboard
• Machine Interface Support
• End of shift reporting 
• Operator Action Security
• Tool Life Tracking
• Labor Tracking
• Label Printing
• ERP Interface/Integration
• Material Usage, Forecasting and Lot Tracking
• Process Monitoring
• Process Variable Overlay
• Weigh Scale Integration 
• Vision System Integration
• Bar Code scanning
• Custom Reporting

Production Monitoring is our standard system that focuses on part counting, reject counting, email/text alerting, tracking uptime/downtime, oee tracking, standard and custom reporting and much more. With over 50 years of experience we have the ability to connect to any machine and other equipment.

The PlantStar system has the ability to measure process variables and provide SPC analysis.  With our extensive background we have the ability to utilize machine interface types like; Euromap, OPC-UA, ModBus, V50/V70 etc.  We also can monitor through an analog interface.  

Collect Process Data for;

• Time between signals
• Temperature
• Pressure
• Position
• Profiles, readings per cycle, X Bar-R
• Process Overlays
  Process Variables monitored are based on the customers wants and needs.  Some common process variables we monitor are; Inject time, pack time, cure time, blow delay time, blow time, transfer time, screw forward, screw rotate, barrel, nozzle and manifold heat zones, mold water zones, and much more. The customer has the ability to set their limits and the PlantStar system can trigger alerts, alarms etc. based on these pre-determined limits.

Track material lot numbers from ERP work order through production and maintain association between material lots and jobs, work orders, and finished goods to provide traceability and control.

Anticipate material usage/demand based on scheduled jobs and materials specifications. Combine material specifications with job scheduling information to forecast material requirements based on schedule. Provides material forecast report and includes calendar of material changeover events.

Tracks the time used and number of cycles that an individual tool was used. Required to access the Tool Maintenance; where information is entered for maintenance performed on the tool.

Create custom end of shift reports which can be automatically emailed to certain users at the end of every shift or multiple times per day.  Some examples are OEE by shift, production reporting, Material usage, reject and down reporting.

Auto-generated data for each time an operator logs in or out into the system.  Auto displays all operators on when they checked into a machine/station and where they are checked in on the shop floor. 

Label printers may be connected via network or directly to a PlantStar DCM and barcode or other labels may be printed for any process requirement.

Customized interface for import/export of production schedules and related information from ERP systems.  We integrate with all ERP/MRP systems.

PlantStar has the ability to broadcast messages related to currently monitored exception conditions. Examples of machine status are; Down, Idle, Fast, Slow, production and prrocess variable exceptions.

This feature allows PlantStar to receive information on good parts that are confirmed as finished goods. A signal is used each time you complete a carton or pallet and PlantStar logs the number of units. We provide push button, sensors and can also interface with printers, scanners, vision systems and weigh scales.

Real-time OEE dashboard that is viewable on any device.  Dial down Availabiliy, Performance and Quality.  Immediate results for Part efficiency, how a machine is running on available time and how you are running against your standard.  End of shift and auto generated reporting available to track OEE.