DataMagic MES – Manufacturing execution system

Manufacturing modes

Different manufacturing modes on shared master data

The manufacturing modes available today are variants of the same document, material-movement and valuation records, so they add up to a single view of production.

Recipe-based process manufacturing

Food, chemicals and blends: raw material to finished goods, according to the recipe.

Processing and series production

Shift-based operation and itemised processing, with output and loss measurement.

Assembly and in-house production

Finished goods from components, with automatic cost calculation.

Routing- and order-driven production

Production by routing and to order, up to custom machine building.

One document and material movement – every production step is created as a stock movement, with no separate interface.
Handling-unit and batch traceability – production items can be identified from goods receipt to finished product.
Standards and performance measurement – expected and actual output in kg per person per hour.
Stock and valuation – cost price and production cost are generated automatically on every production run.

List of production work orders in DataMagic MES: process manufacturing, processing, assembly, routing-driven and made-to-order production in one view, with issued and received kilograms, loss percentage and status

Recipe

From the recipe to the finished product

The recipe describes how much of which raw material a finished product needs. At production time the system calculates the material requirement from it, and posts both the consumption and the finished-goods receipt on a single document.

Finished product and bill of materials – raw material, quantity and warehouse per line, calculated per unit of finished product.
Material requirements planning (MRP) – the full material demand derived from the quantity to be produced, with a stock check.
Automatic recipe-driven stock handling – selecting the finished product sets the required raw materials and quantities.
In-house production on one document – raw material issue and finished-goods receipt in a single step.
Packaging recipe – packaging material on a separate recipe, with flat-film calculation and settlement.
Bulk maintenance – recipes can be adopted, copied and have their raw materials replaced in groups, across several products at once.
Cost price calculation – the production cost of the finished product is built from the value of the raw materials consumed.
Scrap handling – in-process loss on its own posting category, without distorting stock value.

Recipe record in DataMagic MES: the bill of materials for sour cherry jam with per-line recipe quantities, the material requirement calculated for 2,500 kg, the stock check and the packaging recipe

Shift

The shift is the daily frame of production

The shift and the work orders belonging to it appear on one screen, from planning to closing. Every step of processing is created measured and accounted for – from hours worked to downtime and yield.

01 · Opening the shift

Production line, supervisor and headcount broken down by site, from a planned state.

02 · Work orders

The tasks belonging to the shift, with standards and an owner.

03 · Downtime

Stoppages recorded to the working hour, from a hierarchical reason catalogue.

04 · Allocating hours

Hours worked distributed across the work orders.

05 · Closing and reporting

Shift log, performance and loss in one step.

States

Planned, in progress and closed; work orders move together with the shift.

Closing only after full allocation – a shift cannot be closed until every hour worked has been allocated to work orders.
Standard of kg per person per hour – expected output with further identifiers and a correction option.
Loss and yield – the difference between issued and received quantity, and the loss percentage, calculated automatically.
Energy consumption – electricity, gas, steam and water tied to the shift and settled on closing.
Handling-unit reporting and amendment – reporting at handling-unit level, with permission-controlled amendment of the date, the standard and the source unit.

Shift record in DataMagic MES: the work orders of the shift with expected and actual kg per person per hour, downtime accounting from a hierarchical reason catalogue, energy consumption and the state of hour allocation

Routing and production line

Routing, production line, machine data capture

The routing describes the steps of production: which operations run in what order, on which production line and under whose responsibility. The steps travel attached to the production document.

Routing description – the operations belonging to a finished product, with names and sequence, as reusable master data.
Operation steps – the operation, its position in the sequence and its owner, step by step.
Routing tied to the document – the steps are carried onto the production document, so actual execution can be followed as well.
Production lines and line equipment – a register of production lines and the machines on them, tied to the site.
Machine-to-work-order link – which machine produced the task and with how much running time, broken down per machine.
Running time and capacity – the load and running time of production lines as the basis for planning.
Machine interface and data capture – automatic receipt of data from scales, production lines and controllers.

Routing record in DataMagic MES: a seven-step operation sequence with owner, machine and step time, alongside the equipment of the production line with machine hours and a comparison of machine and work-order running time

Traceability

Handling units and batches, end to end

Material produced and consumed can be identified at handling-unit and batch level, from goods receipt to finished product. The handling-unit identifier is an analytical dimension in its own right, and stock, movement and value can all be broken down by it.

Handling unit as a dimension – stock, movement and value can be broken down by handling unit.
Handling-unit type – height, tare weight and mobile identifier, with the properties of the physical item.
Batch and lot – best-before and lot numbers on production items, for shelf-life and quality tracking.
Batch tracking along the chain – consumed and produced batches travel attached to the movements; the link can also be amended later on a correction.
Handling-unit tag and label – a printable tag for physical identification and warehouse movement.
Handling-unit status – the location, quantity and status of a unit in a single query.
Incoming quality classification – quality data of received and produced items tied to the goods receipt.
Tracing in both directions – which finished product came from which raw-material batch, and the other way round.

Batch tracing in DataMagic MES: the source raw-material batches with supplier and lot number, the finished-goods batch produced, the two finished-goods issues, and a preview of the printable handling-unit tag

Made-to-order production and planning

From the order to the planned-versus-actual comparison

Production can also be started from an order, built on the existing document and recipe engine. The production schedule and line capacity give a forward-looking view of manufacturing.

Production order – customer or internal demand turned into a manufacturing assignment, carried through the chain.
Production and packaging schedule – documents for planned manufacturing and packaging, used to reserve capacity.
Planned issues and receipts – planned material consumption and yield ahead of the actual items.
Deadlines and scheduling – production timed against order and delivery deadlines.
Line capacity – the load capacity and running time of production lines as the basis for planning.
Planned versus actual – planned and reported performance compared per dimension.
Production reports – goods receipt and issue notes, contractor job sheets and shift logs as printed forms.

Production planning in DataMagic MES: production orders compared planned versus actual with customer, deadline and completion bar, alongside weekly production-line capacity utilisation with the bottleneck highlighted

Integration

Manufacturing is part of the business event chain

A production step is created in the same document chain as a purchasing, stock or finance item, so the view of production comes together without separate data collection.

Stock and warehouse – DataMagic WMS – a production step is a stock movement, on shared master data with warehouse records.
Purchasing – material requirements become orders, and the supplier chain runs in the same system.
Finance and general ledger – production cost and stock value also flow into the general-ledger posting.
Projects – custom manufacturing can be posted to a project identifier, including on a bill-of-materials basis.
Document management – DataMagic DMS – routing descriptions, quality certificates and handling-unit tags in the document store.
Reporting – production data can be queried in the report designer together with data from other modules.
Permissions and audit log – the field- and record-level permissions of the framework apply to production data as well.

From recipe to custom machine building.