Demo production plant

We invite you to visit the plant whose work is monitored by the IPLAS system. Even though the plant is fictitious and the data is generated, the simplified cycle itself is based on the actual production process of rolled plate heaters.

Highlighted production stages:

  1. Sheet metal cutting and stamping

  2. Welding of parts

  3. Leak test

  4. Degreasing and painting

  5. Firing

  6. Label printing and packaging

    The entire production process is monitored with the usage of the reports listed below.

  • Production - current report
  • Downtime analysis
  • Synoptic map
  • Production summary

The report for current data presents data from the hydraulic press that cuts sheets and presses the heating plates. The first analysis available on it (1) shows the current number of items produced (1a), the estimated end time (1b) and the machine efficiency expressed as a percentage (1c)

Another analysis is the Gantt chart (2), which shows the course of the press work taking into account its downtime. From the chart, you can read what cycles the machine worked in, when there were downtimes and what the reason for them was. The user can create this type of analysis following the instructions available here.

Pie charts are marked with the number (3) another variant of the analysis that was used in the report presented below. The first informs us about the periods of uptime and downtime of the machine, and the second specifies in detail the reasons for stoppages of the devices and their percentage distribution in time. This type of analysis can also be independently generated by the user according to the instructions.

The last analysis (4) available in this report is the table showing downtime for the highlighted reasons.

The Downtime Analysis report covers a machine stoppage during production. It enables data analysis in terms of the total duration of downtimes or their number. The report contains an analysis in the form of a table that informs the user about the cause and length of the stoppages that have occurred for the selected products, as well as which device has failed. Additionally, the data is presented in the form of pie charts. By default, the report is displayed for the current month, however, the user can freely choose the time period for which he wants to generate the report.

The Heaters - current data report is a synoptic map presenting current data for particular areas of the production process. The user can generate this report on his own, initially creating an analysis in the form of a synoptic map according to the instructions. In our case, labels have been assigned to each stage. These labels contain key values such as the number of current orders, the number of leak tests carried out with the number of positive results.

The Production Summary report presents a table that includes data concerning the production start and end dates, quantity ordered and produced, product type, rejection percentage, and order efficiency. By default, all data for the current month is displayed. Additionally, you can search for data from any time period or a specific order by entering the order number or selecting a product. This data can be viewed in the current report or in the generated Excel file.

The second type of analysis of this summary are column charts, the creation of which is described here. They visualize the production efficiency for a specific product depending on the order number. Thanks to the multiple product selection option, the user can decide which charts should appear on the report at any given time.