Expertise and Solutions for the Food Industry

Efficiency and production optimization of clocked, complex lines increase your competitiveness. Short downtimes are eliminated and set-up times are minimized thanks to transparent production lines. We support you in digitalizing your shop floor and in meeting a wide range of requirements. What can we do for you and your production?

Your Digitalization Partner for Reliable Production Control

Consumers expect highest quality standards, extensive standardization and sustainable, resource saving use of raw materials … Our MES not only helps to optimize the production processes, but of course also supports the accurate compliance with strict regulations regarding labeling, hygiene and safety. A ‘production navigator’ not only relieves line managers in production of a stressful daily routine.

FASTEC 4 PRO creates a tangible added value from the shop floor to the company management. Our customers include manufacturers of a wide variety of food products, e.g. meat products, chocolate, convenience food and instant meals, vegan food as well as beverages. With our modular software we produce individual solutions for digital production. Transparent, expandable and adaptable at any time.

Selection of Our Customers in the Food Industry

At a Glance

FASTEC 4 PRO supports you in production in your manufacturing area. Production orders (e.g. from SAP) are planned on mixers and divided into batches according to the capacities of the mixer. FASTEC 4 PRO controls and documents the preparation of work processes. By generating unique package labels, it is clearly defined which weighed components or which pre-mix belongs to which batch.

Time-consuming contents can be digitally organized. Meaningful quality data thanks to correct machine data coming from one software. FASTEC 4 PRO recognizes overdue process controls at any time. The complete order documentation can be traced at any time at the push of a button – regardless of whether it is IFS or BRC. This is how you manage every audit.

This allows you to digitally display and assess the risks associated with the processing of food or finished products in compliance with legal requirements.

In order to avoid incorrect packaging, the products to be packed are checked individually by barcode reading before packaging. In case of a deviation, the process is stopped.

Order, article and lot size can be transmitted directly to the checkweighers, but also to a higher-level systems such as FreeWeigh.NET. The actual weights can be displayed in real time during production. This allows the line operator to intervene to reduce give-away.

Your Advantages in Production Control – at All Levels

Benefits for Production Managers

  • Minimized idle times, reduction of downtimes
  • Fast, targeted response to disturbances or performance losses
  • Identification of deficiencies
  • Improved order and personnel planning
  • Higher throughput thanks to shorter processing times
  • Paperless production
  • Maintenance integrated into production processes

    CONCLUSION: A transparent production minimizes your waste of resources.

Benefits for Machine Operators

  • Continuous target/actual comparison provides up-to-date key figures on order progress
  • Simple recording of all machine and process disturbances
  • Digital provision of order-related documents and monitoring of important process data
  • Order bookings directly at the machine
  • Requesting maintenance in the event of major disturbances

    CONCLUSION: Digital monitoring of the production process guarantees efficient operation of your machines.

Benefits for Maintenance Staff

  • Preventive maintenance is effectively integrated
  • Planning of maintenance takes into account machine utilization
  • Electronic maintenance facilities are provided on site
  • Digital documentation of all maintenance work carried out, including spare parts consumption for all operating resources
  • Comprehensive reports for analysis of maintenance measures

    CONCLUSION: Preventive maintenance and complete, seamless documentation ensure that your machines are well taken care of.

Benefits for Managers and Controllers

  • Reliable, meaningful database to support strategic decisions
  • Continuous performance measurement enables up-to-date key figures
  • Productivity potentials are revealed
  • Savings or margin increase by reducing production costs
  • Optimal CIP analysis tool
  • ROI in less than 12 months

    CONCLUSION: With digitally generated, meaningful reports, you make the right decisions and ensure your company's success.

MES Modules From FASTEC 4 PRO

Module Quality Assurance (QA)

Standard Functions Included

  • Automatic data transfer from peripheral devices/PLC
  • Automatic inspection
  • Data archiving
  • Digital checklists
  • Simple inspection plan creation
  • Intuitive operator entries during production
  • Proactive information management
  • Inspection plans/inspection orders
  • Statistical process controls (SPC)
  • Top level dashboards on large screens

Module Detailed Scheduling (DS)

Standard Functions Included

  • Production variants/versions
  • Gantt chart with drag and drop functionality
  • Comfort functions for an efficient planning process
  • Planning regarding limited work center capacities
  • Testing of rule violations
  • Scenarios with analyses

Optional Extensions

  • Equipment availability planning
  • Material availability planning
  • Personnel availability planning
  • Campaigns/planning groups
  • Changeover matrices/rules, calculation of the set-up times

Module Traceability (TRC)

Standard Functions Included

  • First Pass Yield
  • Forward and backward searches

Optional Extensions

  • Connection to measuring equipment (Q-DAS)
  • Label printer control
  • Material review board (MRB)
  • Material traceability
  • Process traceability
  • Process interlocking
  • Serial number/batch traceability
  • Serial number generator

Module Maintenance (M)

Standard Functions Included

  • Planned maintenance
  • Personnel deployment and requirements planning
  • Alerting
  • Hierarchical structures
  • Maintenance plans/orders
  • Calendar/runtime/counter/state triggers
  • Request and task management
  • MTBF/MTTR
  • Pareto and Pivot analyses
  • Autonomous maintenance
  • Equipment maintenance
  • Synchronization with MDA

Module Machine Data Acquisition (MDA)

Standard Functions Included

  • Intuitive input screens
  • Comprehensive and simple reporting
    – Differentiation of rejects
    – Performance analysis
    – MTBF/MTTR
    – Set-up time report
    – States reports
  • Overall equipment effectiveness (OEE)

Optional Extensions

  • KPI configurator
  • Process data acquisition
  • Process messages (PM)

Module Production Data Acquisition (PDA)

Standard Functions Included

  • Production order management
    – Routings
    – Bill of material
  • Various order types

Optional Extensions

  • Automatic order start from PLC
  • DNC/EDS set data management
  • Document display
    – e.g. training videos, changeover instructions
  • Dynamic target set-up times
  • Energy data collection
  • ERP bookings
    – Recording of quantities/time regarding the production order/start date
    – Automatic reporting into the ERP system
    – Based on packing instructions

Basic Module

Standard Functions Included

  • Audit trail
  • Basic data editor
  • User/rights management
  • Multilingualism
  • Report Designer
  • View Designer
  • Master data management
  • Resource Logbook

Optional Extensions

  • Alerts
  • Connection to BI/BW systems
  • ERP interface
  • Graphical online monitoring (e.g. Andon board)
  • Machine connection
  • Mobile Client
  • Office Client

Are You Interested in or Have Questions About Solutions for Your Company?

We provide customized solutions. With us, you benefit from extensive project experience in digital production in various industries. With over 400 customers. Worldwide. Our consultants can draw on many years of experience from diverse customer projects and can often identify optimization potentials at first glance. In this way we offer you individual, tailor-made solutions. For more than 25 years.