Insight…in context: Connecting to the plant floor.

Data is great. So is visibility. But for user-based analytical tools to drive business goals, they need to visibly connect your objectives to the plant floor.

Our approach to delivering Manufacturing Intelligence and Execution Systems – and ultimately Intelligence Manufacturing excellence and profitability -- is to synchronize operations, equipment and processes at every level.

We provide context-based analysis and visualization tools for unparalleled insight into Intelligence Manufacturing systems.

The systems we have delivered to our clients have helped them to not just understand what’s happening on the plant floor, but also to optimize their operations and utilize their resources effectively to improve their profitability. And our expertise in total Intelligence Manufacturing systems allows us to ensure the integrity of your data so that your ERP investment is delivering optimal performance.

Performance Analysis

How well did your Intelligence Manufacturing system run during the past hour? How about yesterday? How about last month during second shift? Key Performance Indicators (KPIs), such as Overall Equipment Effectiveness (OEE) and others, are used as metrics to measure, compare and communicate performance of Intelligence Manufacturing systems during various production shifts, product runs, etc. The integrity and accuracy of the data used to calculate these metrics is crucial to ensure that you make good business decisions.

Polytron has the plant floor experience and insight to provide you with reliable, real-time and historical, system downtime information that enables you to focus your efforts on the issues that have the greatest impact to productivity. In addition, Polytron has experience with providing unit of operation downtime information that allows you to proactively deal with issues before they adversely affect system downtime.

Production Floor Data Collection, Visualization and Reporting

Access to real-time and historical information is required to understand how your manufacturing systems are performing, how you’re producing compared to schedule, if there are quality issues, status of inventory levels, etc. It is essential that this information be presented in intuitive, interactive reports that are user-based and capable of providing you with the information you need without the clutter of information overload.

Polytron understands that production, quality, maintenance, engineering and executive personnel all need access to plant floor data that is timely, accurate and presented in a manner that allows them to effectively make data-driven business decisions. Whether through the use of 3D HMI graphical screens or web-based reports with drill down capability, Polytron develops the visualization and reporting tools that each user needs to do their part in increasing productivity and lowering Intelligence Manufacturing costs.

Production Planning & Scheduling

Integration of the ERP Production Schedule with that of the plant floor reduces effort and errors associated with re-entering the same data, in addition to a tighter connection between what the Manufacturing Business Intelligence needs, what the plant floor is capable of delivering, and what was actually produced.

Polytron understands the technical challenges, such as buffering and filtering of data, which exist with this type of integration, and designs and deploys solutions to ensure a seamless flow of the information between your plant floor and Enterprise Manufacturing Intelligence system.

Recipe Management

Standardization and version control are key to having an optimal Recipe Management system that ensures old copies (paper or electronic files) of recipes are not being used to run your products.

Polytron delivers Recipe Management systems that are flexible and scalable, and thus can be modified to include new Bills of Material, additional steps, operator prompts, or changes to set points within the framework of the recipe.

Quality Management

Meeting your product specifications while minimizing product giveaway is critical to ensuring a positive customer perception and complying with governmental regulations, while still maintaining a healthy bottom line. Measuring and controlling your product’s quality will typically reduce the product’s variability; reduce product loss due to unnecessary rejects; and reduce usage of raw materials and energy associated with running your process within its optimal boundaries.

Polytron can assist you with delivering a Quality Management solution that will provide you with the information you require to better meet your product specifications; better control your product’s variability; and lower Intelligence in Manufacturing costs associated with these.

Product Tracking & Genealogy

New regulations now require Manufacturers to track their product throughout the supply chain and keep reliable records of the raw material ingredients used to make each product. A well-designed product tracking system will allow you quick access to records that will support you in complying with Good  Practices (GMP) and government regulations, which in turn limits your risk of disruption to your Enterprise Manufacturing Intelligence operations.

In addition, accurate, real-time visibility of your raw material usage, Work-In-Progress (WIP) levels and inventory levels allows for better production planning and limits the impact of any quality issues discovered during or after production runs. Polytron understands the information requirements of a well-designed product tracking system and is capable of providing you with a solution that will enable you to manage your risk and better run your Enterprise Manufacturing Intelligence process.

Certifications & Memberships

Our software development team is experienced in a multitude of automation software suppliers and Polytron is solution provider for several of the best-known technology suppliers, which ensures our development team has access to the training, certifications and support teams necessary to deploy the latest products and features.

Rockwell Control and Process Solution Provider	System Platform Certified System Integrator
Parsec Certified Implementation Partner
CSIA Associate Member	Microsoft Partner providing solutions based on Microsoft products
Mtelligence Reliability Intelligence Program GOLD Partner