Manufacturing execution MES/MOM system COMES

COMES® enables detailed scheduling and digital dispatching of production orders to workplaces. Daily and weekly schedules are automatically generated according to selected criteria (production lines and manufactured products, storage space options, personnel requirements of production, etc.). The input data include production orders from IT (ERP) systems, BOMs, materials, as well as restrictive conditions of the plan, etc. COMES APS shows managers actual status of the production (plan vs. reality) in real time thanks to feedback from production monitoring (COMES OEE). The whole system is freely configurable to create scheduling functions according to customer needs, production organization and technology options, which is in praxis very customer specific.

COMES HRM includes the following functionalities:

• Registers of employees, their qualifications
• Evidence of certificates and completed workhours on machines
• Management and implementation of operator training
• Management, implementation and evaluation of knowledge tests
• Matrix knowledge of employees with automatic update according to acquired process data
• An overview by the operator acquired and required knowledge
• Guarding expiring training, blocking work without the necessary qualifications
• Qualification level of the employee on the basis of acquired knowledge (working under supervision, independent working, trainer).

COMES MOM is usedto control flexible series production processes, from large series down to small series of several pieces. It enables user specification (in the life cycle) of discrete manufacturing operations of the product, their sequence (workflow) and determination parameters of operations. Specifications can be linked to production preparation functions. The created manufacturing procedures are then used as instructions to control manufacturing process.

COMES MOM automatically controls production machines and lines (by communication with their PLC´s) and monitors the status of operations performed. The results of all operations are archived in traceability reports so each product has its own genealogy.

Note: The COMES Batch module is used to control the sequence of production steps of batch production (process part).

COMES OEE incorporate functions:

• Monitoring of the manufacturing process and machine data
• Evidence of downtime and nonconformities
• Management of shifts and teams
• Execution of production orders according to production schedule
• Records of quality and compliance with procedures at the start of production
• Escalations according to production indicators
• Real-time production monitoring
• Reporting for production evaluation and tracing causes of losses
• Analysis of bottlenecks in production
• Creating reports, information screens, Andons, etc.

Production quality management is based on quality controls and management of deviations, incidents, change procedures and investigations.

The concept addresses the following functionalities:

• Management of code lists (materials, suppliers, production orders, non-conformities)
• Evidence and management of meters (location, use, repairs, cleaning, documentation, calibration)
• Check procedures (types, parameters, frequencies, states, connected documents)
• Implementation and registration of inspections (manual entry of results, data from connected measuring instruments)
• Records and proceeding of complaints (input materials, customer complaints)
• Evaluation of suppliers
• Automated monitoring, data collection and reporting of critical production operations
• Reports and statistics (equipment capabilities, SPC, ...).

The COMES LAB concept is used to control the quality of batch production. It solves the whole process of material control from raw materials to the release of the produced batches to the custom

Selected functions:

• records and documents: Material specifications
• Material regulations of analysis
• Sampling plan (records all samples, sampling plans and tracing of their movement and consumption)
• Results of analyzes, setting of material states (blocked, released, ...)
• Archiving of partial measurements from devices
• Preparation and reporting of auxiliary chemicals (records of opiates, carcinogens,…)
• Management of instrumentation (calibration, control, adjustment based on real use)
• Management of training analytical regulations and instruments
• Plans of microbiological monitoring, re-analyzes and stabilities.

COMES LAB can be connected with all other systems in production, gains the necessary data from them. On the basis of data evaluation the QA/QC department can make relevant decisions and digitally send results and instructions to production users.

A comprehensive solution for the factory‘s internal logistics includes:

• Warehouse processes - purchase and storage of materials, warehouse products, shipping, inventory
• Supply to production and its workplaces, machines and lines (control of AGV trucks etc.)
• Functions for production, quality (connection with COMES OEE and QMS)
• Accurate registration using bar / RFID codes
• Automatic traceability
• Registration of batches, expirations and suspensions
• Material flow management (FIFO, FEFO principles).

The benefits of users include:

• Improving the organization and work of warehouse staff (work queues, prioritization of logistic operations, route optimization, automatic checks)
• Optimization of transport routes of materials
• Overview of the state of the warehouse in real time
• Automatic escalations and instructions
• Inventory monitoring
• Connection with ERP systems, production systems (equipment, lines, control stackers and conveyors).

COMES Maintenance solves efficient and user-friendly management of plant maintenance via mobile devices (tablet, smartphone) directly at the machines. It serves both small and larger, structured teams. The application can be installed separately, but a great advantage is the possibility of connection to the entire COMES system with its complex MES / MOM functionalities. In conjunction with the collection of machine operating data, it will allow users to effectively plan maintenance.

COMES Maintenance uallows you to:

• Specify maintenance resources and items
• Visual maintenance planning in various modes (periodic, preditive, immediate)
• Cooperation of production and maintenance, documented handover of equipment
• Records performed actions (even unplanned ones)
• Support of processes of regulated industries (GMP)
• Management of spare parts warehouse
• Communication with external systems (control systems, corporate IT systems, ERP)
• Maintenance evaluation in the form of reports, statistics and protocols