Concern Guelder-rose (MEScontrol)

Situation

Kalina concern the leader not only in the market of cosmetic medicines, but also the leader in the field of effective business. This modern enterprise which is able to estimate solutions in information technology field and automation. At the time of the beginning of the project the company had rather strong solution of SAP, the most part of technology processes was automated by the PCS complexes and SCADA. But full communication between ERP and the PCS at the enterprise was not. Moreover a part of production processes was not automated.

Assigned tasks

In the fall of 2012 the Kalina concern made the decision on MEScontrol implementation. The following directions should undergo automation:

• Automation of work of technologists regarding work with Loading Orders.
• Transfer of information exchange and document flow on section the TECHNOLOGIST WORKSHOP in an electronic format.
• Control automation by production process. From planning of loading of the production centers to the analysis of results of work of technology complexes.
• Transfer of decision making from technologists and operators to a system. Decision making process is based on the data put in a system and received from the equipment.
• Control of calculations and actions of employees.
• Possibility of modeling of new production processes and mastering of new products without real loading of the equipment.

Benefits from MEScontrol

At the moment the MEScontrol system it is implemented in two workshops of Kalina concern and includes:

• 9 work centers
• 19 jobs of personnel
• Modules:
• Plan of the enterprise
• Command center and data processings
• Products
• Security
• Operator
• Knowledge base
• History (Track&Trace)
• Reports
• Warehouse
• Acceptance

In the field of control and personnel management of workshop the goals are achieved:

• Functions of production personnel passed from industrial process control to control of production process indicators.
• Reduction of requirements to level of training of operators
• Exception of errors and bad faith of operators
• Manual calculation of quantity of components to order is stopped
• Automation by a work routine
• E-learning

New opportunities became available to technologists of concern:

• Electronic base of compoundings and orders of loading
• Control of an order of loading on correctness
• Version control of an order of loading
• Filling of an order of loading on ready templates
• Control of accomplishment of an order of loading on the reactor without leaving a workplace
• History of accomplishment of an order of loading
• Calculation of new compoundings and specifications without full-fledged utilization of capacity.

Result of implementation of MEScontrol for the management of concern:

• Runtime of the order is reduced by 25% due to reduction of manual transactions
• Decrease in influence of a human factor. Exception of errors and factor of bad faith of personnel.
• Reduction of requirements to knowledge and experience of production personnel.
• Increase in culture of production and transparency of decision making.
• Reduction of defects and runtime of orders
• Input of new products and production technologies becomes simpler and cheaper.
• Increase in accuracy of cost accounting of products. Additional possibility of cost optimization.
• Cost reduction of the enterprise, including expenses not personnel.