Our MES Software and Industry 4.0 Solutions

Smart factory in a few steps

Our Industry 4.0 Solutions

Smart Factory in a few Steps

MES solutions offer an ideal basis for the increase of efficiency in your company. The MES software developed by the iMes Solutions GmbH works as a connector between the IT world and automation processes and, it offers solutions for the optimization of operational production processes . The results are competitive benefis and a gapless tracking of quality and production data.

Plant scheme Product innovations

Solutions for Your Production Processes

  • Warehousing & Logistics
  • Operating Manager
  • Production Manager
  • Service & Maintenance
  • Support
  • Operator
  • Head of Department
  • QM

Warehousing & Logistics

Benefits:

  • Transparency reaching from incoming to outgoing goods
  • Gapless documentation of goods movements
  • Intuitive tool for permanent and periodic inventories

Dependent modules

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Operating Manager

Benefits:

  • Production transparency: identification of bad processes, increase of plant availability (OEE)
  • Automated reporting, e.g. daily reports
  • Improved communication – within the department – interdepartmental – external – with auditors and suppliers

Dependent modules

Production Manager

Benefits:

  • Production transparency: identification of bad processes, increase of plant availability (OEE)
  • Automated reporting, e.g. daily reports
  • Improved communication – within the department – interdepartmental – external – with auditors and suppliers

Dependent modules

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Service & Maintenance

Benefits:

  • Predictive Maintenance
  • Central and consistent recording of maintenances measure
  • Automatic notification of maintenance requirements

Dependent modules

Support

Benefits:

  • Gapless life cycle documentation of all production events
  • Direct information availability in production
  • Right decision at the right time

Dependent modules

Operator

Benefits:

  • Paperless working: reduction of manual data collection work
  • Support for plant operation (e.g. the plant operator is guided throughout the production process with the help of scanners or mobile devices)
  • Support in cases of alarm flooding  -  less alarms mean less work for the operator

Dependent modules

Head of Department

Benefits:

  • Automated reporting – KPI reporting
  • Availability of relevant key figures (e.g. OEE)
  • Improved communication – within the department – interdepartmental – external  - with auditors and supplliers
  • Support for audits

Dependent modules

Quality Management

Benefits:

  • Supported quality check, e.g. automatic transfer of measured values
  • Supported reporting
  • Direct information transfer in cases of quality inconsistencies

Dependent modules

Plant Historian

Modular Software Suite

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 for 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.

Benefits

  • Transparent production
  • Order cockpit, shift reports weekly, monthly and yearly
  • Optimized communication within and outside the enterprise
  • Smooth and transparent information flow within the department, with other companies, auditors, suppliers and clients
  • What was producesd when, how and where (tracking & tracing) ?
  • Increase of Overall Equipment Efficiency (OEE)
  • Paperless working: central and digital acquisition of productino data and automatic filling of Excel lists
  • Automated reporting of KPI and OEE key figures
  • Man-machine-networking: direct exchage with ERP and PCL/SPS-W

Plant Historian AM

Alarm management for more plant safety and transparency

Our MES software Plant Historian AM – alarm management – is a company-wide applicable, central solution for the long-term archiving and analysis of your process control system. The comprehensive analysis functions support structured procedures for alarm reduction and plant optimization. Sustained 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.  

Systematic alarm management by means of the MES solution Plant Historian AM – Alarm Management – can be applied in smaller and  big enterprises. Company-wide solutions with more than 300 servers are possible without any problem.

Benefits

  • ƒIncreased plant safety and availability
  • ƒIdentification of bad operation processes
  • ƒSupport with the objective of an alarm reduction

Functions

  • ƒAlarms & events - frequency evaluation and distribution
  • ƒKPI reporting according to ISA 18.2, NAMUR NA102 and EEMUA 191
  • ƒDirect alarm forwarding per SMS, email, phone
  • ƒVisualization of upcoming / past disturbances

Plant Historian AR

Alarm rationalization for increased plant safety

Alarm rationalization refers to the comparison of alarms with the actual alarm system as well as the determination and documentation of alarm reasons.  Alarm rationalization comprehends the configuration of alarm parameters.

An important part is the detection of possible consequences and the determination of corrective measures including alarm priorization. The latter is usually based on the consequences which would arise in cases of alarm ignorance. (damage to human beings, environment and machine) and the time remaining for the operator to react.

Instructions and recommendations for action represent an additional optimal support for the operator.

Alarm rationalization, sustainable alarm management
Alarm rationalization, sustainable alarm management
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Benefits

  • ƒIdentification of bad operation processes
  • ƒStatistical evaluation of alarm frequencies and reaction times

Functions

  • ƒIntuitive classification of alarms
  • ƒBasis for the Management of Change process (MOC)
  • ƒValidation of rationalization measures (comparison of planned and actual data)
  • ƒAd hoc evaluations concerning alarm frequency and length
  • ƒAutomatic generation of alarm master data

Plant Historian PDA

Process data archiving: recording, analysis and archiving of process data


The MES software Plant Historian PDA – process data archiving – is a central system for archiving, recording and analysis purposes concerning process data. Plant operators benefit from the completeness and company-wide availability of process data and, from the intuitive and comprehensive analysis functions. Plant Historian PDA - process data archiving - offers support for quality management and plant safety. A consquent and transparent process data collection reveals optimization potentials and their sustainable realization. 

The MES software Plant Historian PDA – process data archiving – is a flexible and powerful process information system for the optimization of internal and external communication. Information recipients ares supplied with relevant process information and are able to react at an early stage.

Benefits

  • Quality management and process optimization
  • Optimization of internal and external communication
  • ƒTransparent visualization of the plant condition

Functions

  • ƒNumerous analysis tools and display options
  • ƒTrend display with visualization of the related messages issued by the process control system and direct display of limit value violations

Plant Historian DIG

LIMS: laboratory information and management system - recording and administration of laboratory data and manual values

The MES sofware Plant Historian DIG - digital data acquisition - is a system for the central collection and evaluation of laboratory data and manual values.

Users of the MES software Plant Historian DIG benefit from the high safety and security  concerning data collection and the fast reaction possibilities in cases of limit value violations. The configuration of the input mask is possible without any programming effort by the user. For the output of centrally collected data, there are shift or production reports available. Paperless data can be issued in any specification as reports. Finally, paperless data collection facilitates research for special results.

Benefits

  • ƒCentral paperless data collection
  • ƒOptimized reporting
  • ƒSupport for internal and external audits
  • ƒEscalationin cases of limit value violations and indiction of procedure instrctions
  • Simple research

Functions

  • Manual or automated recording of manual values
  • ƒManual or automated reporting
  • Numerous analysis tools and visualization options

Plant Historian RM

Reporting and report management

The MES software Plant Historian RM - reporting module - is a central system for production relevant reporting like shift reports, audit and batch protocols or shipping documents. The transparent reports represent a support for internal procedures as well as for the cooperation with customers and partners.

Plant Historian RM provides a flexible report management, which is adaptable to any needs.  Recurring reports like shift reports or daily evaluations can be regularly  forwarded to predefined recipients.

Benefits

  • The right information at the right time for the right recipients
  • Automated generation and distribution of KPI and OEE reports
  • Use of existing Excel Excel templates

Functions

  • ƒOutput of reports as PDF or in Excel
  • ƒAutomated distribution to predefined recipients
  • Any type of reporting: shift reports, daily and monthly reports etc.

Plant Historian EM

Energy control and monitoring according to ISO 50001

The MES software Plant Historian EM - energy management - is an energy monitoring and control tool for the complete registration of energy flows and for the identification of energy potentials including their realization. Users benefit from data transparency, detailed visualization options and the possibility of energy cost control and optimization.

The MES solution Plant Historian EM - energy management - provides energy monitoring and control as a basis for an ernergy management system according to DIN EN ISO 50001.

The MES software module Plant Historian EM - energy management - has been classified as an eligible energy management software by the Federal Office of Economics and Export Control (BAFA).

The targt of the collection of consumption data is the recognition and prompt correction of excessive consumptions. Increased consumptions are discovered and are a basis for detailed analysis and subsequent savings measures - with the result of a sustainable realization of optimization potentials and a reduction of energy cost.

Benefits

  • ƒTransparency of energy data
  • ƒAutomated reporting of energy data
  • ƒReduction of energy cost
  • ƒSustainable management
  • ƒEnhanced image

Functions

  • Consumption analysis
  • ƒEvaluation of cost centers
  • ƒVisualization options
  • Validation and alarming of balancing groups

Plant Historian MDE

Machine data acquisition

The MES software Plant Historian MDE - machine data acquisition (MDA) - is a system for the central collection, monitoring an analysis of machine data. Plant Historian MDE - machine data acquisition - is a tool for gapless acquisition and recording of machine data and, the transparent presentation of relevant information - thus providing efficient monitoring and analysis of machines and processes. On the basis of the recorded data, there are possibilities for the identification of optimization potentials and the coninuous improvement process.

The clear visual presentation of the collected machine data and an intuitive system operation represent a guarantee for  transparency during manufacturing operations and during the continuous improvement process (CIP). On the basis of the recorded machine data, the calculation of different key figures and benchmarking are possible.

Benefits

  • ƒTransparent presentation of the machine status
  • ƒPrompt identification of differences
  • ƒIncrease of machine availability

Funktionen

  • ƒAcqusition of technical operating data
  • ƒCalculation of key figures and benchmarking
  • ƒTransparent monitoring and analysis of machines

Plant Historian OEE

Overall equipment effectiveness

The MES software Plant Historian OEE - overall equipment effectiveness - is a  recording, analysis and documentation tool  for unexpected losses and plant standstills ( unplanned lack of staff, plant disturbances ...). Overall equipment effectiveness is the product of the following factors:

  • availability
  • performance
  • quality

Overalll equipment effectiveness (OEE) is calculated on the basis of the above mentioned recorded factors. On the basis of OEE, it is possible to create transparency of the value added for each single plant of the production line - which provides, for instance for the management, the possibility of a differentiated view on the plant and, as a result, on the value added of the whole production.

Benefits

  • ƒTransparent presentation of production data
  • ƒImmediate recognition of divergences
  • ƒIncreased availabilty due to direct information forwarding concerning the machine/plant status

Functions

  • ƒRecording of technical operation data
  • ƒCalculation of key figures and benchmarking, e.g. overall equipment effectiveness
  • ƒTransparent monitoring and analysis of machines

Plant Historian HMI

Visualization of manufacturing/production processes

For the plant operator, the module Plant Historian HMI - visualization - offers the possibility to visualize different production key figures per drag & drop:

  • machine data (MDE)
  • visualization of manufacturing and production units
  • alarms and events
  • OEE key figures
  • actual process values

Benefits

  • ƒƒFlexible plant monitoring
  • ƒAbstract display of plant status and information aggregation
  • ƒInterlinked display of decentral machine and production units
  • ƒTransparency due to information networking (Big Data)

Functions

  • ƒFlexible dashboarding per drag & drop
  • ƒPersonalized layout saving
  • ƒMultiscreen splitter
  • ƒDisplay of alarms & events, process or machine data, OEE key figures on one surface

Plant Historian SB

Digital shift book

The MES software Plant Historian SB - shift book - is a central system for the acquisition and documentation of shift events.  Instructions, shift information and events are registed and archived company-wide and uniform. The integration of  client-specific check lists and forms into the shift book is possible, too. Data are collected completey and in accordance with the law along the whole production chain.

The MES software Plant Historian SB - shift book - provides revision-proof and gapless recording of shift information along the entire production chain - with the result of time reduction concerning data acquisition, reporting and research, an increase of  process quality and the optimization of machine capacity and error costs.

Benefits

  • ƒReduced data acquisition, reporting and research efforts
  • ƒOptions for statistical evaluation
  • Simple operation

Functions

  • ƒDocumentation and recording of shift events
  • Individual generation of shift plans
  • Revision safety
  • Hierarchical report function

Plant Historian PM

Predictive Maintenance

Plant Historian PM provides the possibility of a preventive reaction concerning machine disturbances and standstills. Predictive Maintenance reduces downtimes, saves operational ressources and decreases maintenance costs.

Predictive Maintenance provides permanent equipment (assets) – by using sensors measuring, for instance, vibration, temperature or humidity.
Predictive Maintenance provides action instead of reaction.

Benefits

  • Reduction of downtimes
  • Predictive planning of maintenance measures
  • Planning reliability in production

Functions

  • Monitoring of maintenance-related data
  • Recognition of maintenances tendencies as a result of data accumulation (Big Data)
  • Recording of maintenance measures

Plant Historian PPS

Production planning scheduling

The MES software Plant Historian PPS - production planning scheduling - is a central system for the operative planning and control of production processes (production control).

The MES software PPS provides support for the realization of short process times, deadline compliance, optimal stock quantities and the economical use of operating material. Users of Plant Historian PPS benefit from recording and feedback of production results (actual data). The collected and confirmed data are considered for future plannings.

The connection to an ERP system ensures the integration of personal and financial resources.

Benefits

  • ƒSupport for production planning (orders, material, staff)
  • ƒ Warehouse supply and demand information
  • ƒOrder control
  • ƒStructuring of the manufacturing process
  • Capacity planning

Functions

  • ƒProduction control with order sequencing according to different guidelines
  • ƒMaterial requirements planning based on parts lists, batches and order quantities
  • Lead time scheduling
  • ƒTime and capacity planning
  • ƒInventory management with goods receipt and goods removed under consideration of security, order and stock quantities
  • Availability check

Plant Historian PTT

Traceability of process data

RFID helps to document, which material is intended for which production unit (furnace, casting machine, packaging units ...) - thus avoiding the supply of any material to the wrong production unit.

The system is installed on lift trucks, elevating trucks and trucks. It collects, documents and controls material withdrawals and accompanies any material activity throughout the whole production process. All the recorded parameters like date, time, weight and temperature as well as any information on production units are checked for plausibility. This process prevents the materials from getting to a wrong production place.

The correct procedure is displayed by order. For special batches, cleaning, emptying, maintenance and makeready processes, there is a special procedure wth required password release.

Benefits

  • ƒTraceability of the collected data
  • ƒError-free flow of material
  • ƒPlanning and control of the material flow
  • ƒRight material to the right production unit

Functions

  • ƒComponents suited for melting or foundry (temperature and dirt-resistant and unaffected by vibrations)
  • ƒIntuitive user interface