Londonderry, New Hampshire, February 25, 2016 – The new MDT-20 from Production Process is a universal, real-time data collection and production scheduling interface between all types of discrete manufacturing and ERP.

Most ERPs do not inherently support integration with production operations, even though it affords significant operational benefits. The difficulty lies in the variety of machines found on the production floor, typically with no, or incompatible data communications technologies. The MDT-20 provides a bi-directional link to any discrete manufacturing machine, plus it adds intelligence in the form of production, performance and Job progress data and information typically not available from a PLC or machine control. Optionally, a Tablet PC can be added serve as a low cost Operator Interface/HMI.

To collect data the MDT-20, one installed on each production machine, collects manufacturing data from four machine operating electrical on/off signals. It continuously monitors machine cycle times and rates, part and reject counts, down time, and calculates KPIs such as overall equipment effectiveness (OEE Software or OEE Monitoring). Data is transmitted via standard wired or wireless Ethernet to supporting Windows software.

The MDT-20’s bi-directional communications provides an automated export to ERP/MRPII of production and performance data for reporting, analysis and inventory updates. Additionally, the import of Master Production Schedules to individual machine Job Queue facilitates dynamic production scheduling and real-time Job completion tracking. Optionally, a Tablet PC can be connected to the MDT-20 to provide data entry and real-time production, performance and equipment OEE dashboards.

Says Karl Ritzinger, president of Production Process, “With the MDT-20, we provide a practical, economical, universal and productivity-improving connection between literally any discrete parts manufacturing process and ERP, regardless of the production equipment’s vintage or intelligence”.

The benefits are many. Automated data collection and export to ERP/MRPII eliminates the inefficiencies, time delays and errors of manual production data collection and entry to bring overall equipment effectiveness. Tracking Work in Process and Rejects/Scrap in real time improves inventory accuracy and minimizes the need for “safety stock” and routine physical counting. Analysis of causes of down time and key performance indicators such as OEE reporting or OEE tracking helps improve utilization of production assets, and provides a foundation for Continuous Improvement and Lean Manufacturing initiatives. Management can quickly identify underperforming machines, both visually and through e-mails alerts that show the status and performance metrics for any machine or work center. Accurate Job costs can be determined by analyzing historical data such as setup time, run time, down time, cycle time and production rate and OEE monitoring against Job standards.

The optional Tablet PC HMI an provide a low cost Operator interface for display of real-time manufacturing productivity dashboards as well provide for Operator entry of down time reasons, rejects and Job change requests. Keeping the Operator informed of his progress and involved in the operation and maintenance of his machine is an essential part of a Total Productive Maintenance (TPM) program and Lean Manufacturing initiatives. .

To improve scheduling accuracy the system imports Master Production Schedule directly into individual production machine Job Queues. The system then accurately calculates the start/finish times of individual Job orders based on real-time operating conditions, the shift production schedule and efficiency factors related to the individual Job or machine. Now, Production Scheduling and Sales departments have a real-time view of the status of customer orders and their completion date. What-if production scheduling changes can be made without disturbing actual schedule, and jobs projected to be late are flagged immediately. At Job and Shift end files are generated for feedback to ERP/MPRII on Job starts and completions, along with automated inventory and Work in Progress updates

MDT-20 costs $1,200 (quantity one) and is supported with three levels of system software: OEE Manager, Production Manager or Job Manager.

Production Process (www.productionprocess.com) develops custom controls and instruments for production operations. Several hundred systems operate in discrete manufacturing operations of all types and sizes, including many Fortune 1000 companies.

For more information about Production Process’s MDT-20 or production monitoring software please visit https://productionprocess.com/machine-data-collection-production-oee-data/

About Production Process
Production Process was founded in 1972 to develop custom controls and instruments. Industry acceptance of our patented single function data display instruments (30,000 in the field) led to the development of intelligent communicating, multi-function instruments—Machine Data Transducers (MDT). Our supporting Windows software – ProductionACE—continues to evolve with additional capabilities. Because of its simplicity and “universality” of application, our systems are being installed in every type of manufacturing process. Production Process sells, supports and services its products from its Londonderry, New Hampshire, U.S. location. For more information visit us at: https://www.productionprocess.com