Elemco Enterprise Shop Floor (ESF) targeted areas for efficiency gains:

ESF’s ERP package:

>  All supply chain master data and activities are maintained in a single place including material and bill of material creation, supplier information, forecasting, scheduling, procurement, receiving, warehouse management, inventory control, quality control, batch control, finished goods production, component consumption, customer order creation, shipping and financial reporting.

>  Systems are designed for stream-lined inventory flow of material from enterprise wide warehouses to local staging areas to production lines

>  Inventory statuses are constantly monitored  to ensure allocated inventory remains usable

>  Material suppliers can use the Third party Portal to accept POs and view inventory levels for their materials

>  Using Setup scan procedures we can confirm initial componentry has been brought to the allocated area prior to beginning production [i]

>  During finished product labeling we can enforce “How Did You Make This tm” analysis and facilitate real time component inventory reconciliation

>  Software as a Service (SaaS-cloud) design allows for immediate use with minimal internal cost for technology

>  Tiered support packages are available based on your organization’s working hours and time zones

Data Collection Line Monitoring:

>  Facilities can visualize real time occurrences of down time due to production lines not running or running out of standard parameters [ii]

>  Warning emails or text message can be sent to personnel when equipment shuts down due to a fault, based on the total number of rejects produced or continuous number of rejects produced [iii]

>  ESF’s captured data can be used to audit and adjust standards within cGMP framework [iv]

>  ESF’s captured data supports lean manufacturing initiatives (such as OEE and TPM)

>  Potential future gains may be achieved by Operations and Supply Chain personnel to analyze ESF’s captured data along with supply and demand reports in pursuit of production leveling practices[v]

Automatic Replenishment:[vi]

>  After presented with a master schedule, production supervisors are given a visual confirmation of which jobs can actually run based on current usable inventory [vii]

>  Multiple jobs can be simultaneously staged to reduce down-time between production runs

>  Inventory is allocated (and can only be scanned) to specific staging racks and production lines to prevent misplacement and double handling [viii]

>  Inventory pick lists can be batch specific and are generated giving preference to partial and first to expire containers, preventing unnecessary aging [ix]

>  Real-time burn down algorithms analyze actual run rates and actual produced quantities to determine component replenishment needs for each production line

>  Replenishment requests are component / line based, avoiding one production line from getting unneeded components while another line suffers from lack of components

>  Facilities can visualize real time occurrences of replenishment requests, delays in fulfilling the requests, down time due to requests not being fulfilled [x]

>  Previously allocated inventory at the staging racks can be reallocated to “other jobs” without first going back into the warehouse

>  Opened containers at the production lines can be set to mandate QA approval prior to use on other jobs

Integration to Corporate Systems of Record:

>  ESF’s modular design allows companies to choose which business functions are used in ESF

>  Integration and compliance with corporate systems of record can be achieved with near real time data flow

>  Production lines can be ended (or stopped short) and set-up can begin for the next production run while master systems are calculating the closing procedures

>  ESF’s data can be interfaced into the corporate reporting (BI) solution or an advanced Enterprise BI solution can be obtained from Elemco for central data reporting [xi]


[i] As not all materials will go into staging this can be set to only confirm staged components

[ii] This can be viewed on large displays or externally on internet connected devices (Laptops, iPads, Tablets or smartphones)

[iii] This feature assumes your equipment can segregate rejected material.  SPC data can be used if available.

[iv]Additional PLC installations can be purchased if specific equipment needs to be monitored

[v] Elemco’s services can be obtained to facilitate meetings of cross functional teams

[vi] This add-on module needs data collection equipment on the production lines

[vii] Exception lists are created for components assumed always available (JIT, storage vats, etc.)

[viii] Learning’s from Lean manufacturing best practices

[ix] Algorithms can be modified based on local plant operations

[x] This can be viewed on large displays or externally on internet connected devices (Laptops, iPads, Tablets or smartphones)

[xi] Our Enterprise Bi solution is powered by QlikView and requires additional licenses