Solutions for Fast Moving Production Lines

Filling and packaging lines with fast cycle times characterize the consumer goods and pharmaceutical industries. Regardless of whether it is simple pass lines or lines with integrated ovens or cooling sections – we have the right solution for you.

Our Solution Offering for Digitalizing Your Production Lines

Transparency is a top priority for our customers, especially when it comes to complex and expensive lines. Our module Machine Data Acquisition (MDA) and the additional function Monitoring provides you with the answers to the following questions: How well are our lines running? What problems does the bottleneck machine cause? Are we still on schedule? When do we have to supply the material for the next order to the line? How long do our set-up changes take? What is more, the digital processing of checklists play an increasingly important role for our customers. With our module Quality Assurance (QA) you can easily define at what particular time the line operator has to enter which data at the production terminal. Paper notes and the subsequent scanning are thus finally a thing of the past.

Depending on customer requirements and desired level of detail, a line is either displayed as one workstation only; however, each machine can also be displayed individually. This is often necessary when different parts of the line or different orders run through ovens or cooling lines. The great flexibility of FASTEC 4 PRO is particularly evident in the connection to the control level. In the simplest case, lines are connected via digital I/O modules. In this case, it is already possible to realize an MDA with manual entries. However, if more information is to be read out from the controls or if data is to be written in the controls (e.g. order data or machine parameters), OPC UA or native drivers, such as TIA Portal, are used.

Selection of Our Customers With Line Production

At a Glance

The monitoring and alarm system provides you with all relevant information you need to control your production. Online and in real time. This allows you to react and intervene quickly, saving you valuable production time.

In the ERP system, a fixed set-up time is often stored for each article. In reality, however, the target set-up times depend on the previous order on the line. Is it a batch change, a country change or a format change? With the possible individual extension “dynamic target set-up times” of our module Production Data Acquisition, it is possible to store these dynamic target set-up times in set-up matrices in order to better evaluate the efficiency of set-up processes.

FASTEC 4 PRO is delivered with many flexible evaluations. This way, you do not need to know exactly what to evaluate in advance. Whether you want to evaluate by shift, day, week, month or year; all settings can be combined with line, order or article.

Controls carried out during the production of an order or batch are often still documented on paper. In practice, it is up to the line manager to make sure controls are carried out on time. With our module Quality Assurance (QA) the line operator is reminded to carry out the inspection at the right time. The results are immediately available online and ensure quick reactions in case of deviations.

Even today, many companies still plan their production in Excel. Area by area. With our planning module, you can schedule the orders from your ERP system to the lines in no time. Order progress and delays are visualized clearly.

FASTEC line concept: Representation of a food line

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
  • Samples/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 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 setup 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
  • 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
    – Setup 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 setup times
  • Energy data acquisition
  • 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.