Expertise and Solutions for Metalworking Companies

The digitalization of production processes and the acquisition of valid data in real time are essential for metal processing companies. We are the partner at your side on your way to paperless production and have the right solutions for your industry.

Your Digitalization Partner for Reliable Production Control

Whether it’s machining, stamping and forming, foundry or wire drawing – the challenges in metal processing are multifaceted. We are your MES partner with the suitable software solution for your digital and efficient production – paperless, in real time and transparent. With our software FASTEC 4 PRO, we support you in digitalizing your production.

We speak the language of machines in the metalworking industry: Our module Machine Data Acquisition (MDA) reads out information from the machine control via interfaces, among other things to the NC control and thus guarantees clean data acquisition at all times. As part of ensuring quality and the ability to act in the event of a defective part, FASTEC 4 PRO offers you complete traceability. Thanks to the complete data acquisition at the material and process level you can access clear forward/backward evaluations.

Selection of Our Customers in the Metal Working Industry

Special Requirements in Metal Working

Everything from individual systems to large machine parks is used for metal-cutting manufacturing. As a rule, this type of metal processing involves both clocked processes and longer production cycles. This is why it can sometimes be challenging to record the exact running time of a workpiece – especially in systems with fully automated pallet changers. We have the solution: Our MES is connected via NC controls. With our PDA module, the order start can be read automatically from the controls. This guarantees exact, item-specific data acquisition in real time. In this way, you enjoy absolute transparency, which guarantees an exact post-calculation for the orders and articles. This is the basis for a clean, article-related OEE calculation in your production.

Strokes per minute and tool-related processes characterize production in stamping and forming technology. The tool is very important and must therefore function smoothly at all times. Even slight damage can lead to considerable production errors. With FASTEC 4 PRO you always keep an eye on your tools:

  • The tool management always displays the current status of the tool and immediately informs you about any irregularities.
  • Our MES shows you the OEE evaluation at tool level – in this way, you always have an overview.
  • Preventive maintenance minimizes the risk of tool errors.

No more inaccurate stocks and easy booking according to packing instructions – no problem with FASTEC 4 PRO. Paperless Production Data Acquisition ensures, for example, the order-/article-specific OEE recording of left and right parts. This enables you to achieve maximum inventory accuracy.

We also have a suitable MES solution for the industry-specific production processes “wire drawing” and “stranding” – for example, with the use of reels, spools, rollers or during the hardening of drawn or stranded material in continuous furnaces, etc. For this purpose, we measure in meters per minute in accordance with the length production. Thanks to our many years of extensive and cross-industry experience, we are highly skilled when it comes to connecting machines (MDA/PDA). Our software automatically transfers the data from the machine control – you enjoy transparency in real time.

Find out how and where a product was manufactured at any time – complete traceability of production processes and materials is essential nowadays. FASTEC 4 PRO offers the appropriate solutions for this – forward/backward evaluations at both the material and process level.
Some advantages:

  • Obligations to produce proof are fulfilled (particularly relevant for automotive suppliers).
  • Operations are reliably carried out in the correct sequence. The process quality is thus ensured.
  • Exact documentation down to the process level is made possible, for example by connecting measuring machines (Q-DAS).

Using digital checklists, the machine operator can check his own activities and carry out individual test steps independently (operator self-inspection). Our MES software provides event-based inspection orders configured according to individual specifications. This ensures a smooth production process as well as high product quality and provides paperless documentation.

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 weaknesses
  • 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 equipment
  • Comprehensive reports for analysis of maintenance measures

    CONCLUSION: Preventive maintenance and complete, seamless documentation ensure that your machines are optimally supplied.

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 Do You 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.