RDL Technologies Pvt Ltd - IoT, Internet of Things, Iot, Lifi

RDL MES 4.0

Every manufacturing unit's success depends on effective planning and scheduling based on a variety of shop floor dynamics (machine availability, operator availability, raw material, production lead time, breakdown and vendor process, etc.). It also involves identifying the specific losses that lead to low machine productivity, as well as procurement, sales, and finance, as well as closely monitoring market trends.

The RDL MES 4.0 Manufacturing solution integrates IT and OT to drive end-to-end digital transformation across the enterprise through the integration of industrial AI and IoT. Our cloud-/on-premise-based solution helps digitize day-to-Day manufacturing processes , improving operational efficiencies, asset performance, productivity, utility consumption and wide-scale sustainable value creation.

Architecture Diagram

MES 4.0 system for smart manufacturing

Key Advantages

Integrated Shop floor & ERP.
End-to-end Traceability.
Customized for your manufacturing industry.
No third party is involved. Development & Support will be directly given by RDL.
Regular automatic updates as per industry-specific best practices.
Support both Cloud / on-premise.
100+ Happy Customers.

Planning & Production Control- PPC

Option for viewing forward machine availability for jobs, current machine loading / capacity utilization and projected machine utilization & availability for a given time frame.
Smarter production planning and traceability - Real-time production visibility like target vs produced across shifts, hours.
Shop floor / machine schedule planning, heat treatment schedule planning assembly and testing schedule planning based on real time dynamics (Machine Availability, Manpower Availability, Production Defect, Monthly / Quarterly Production target and Project Hold by the customer).
Schedule / Reschedule / Machine downtime alert to respective stake holder.
Descriptive analytics with historical data to analyze trends in production.
Job card generation based on BOM and item vs process.
Material requirement planning based on BOQ.
Generation consolidated raw material requirement & BOI to purchase.
Option for importing contract list / sale order to segregate regular production parts, R&D parts & MKD parts.

Industry 4.0 enabled Manufacturing Execution System

Operators & Job Cards

Real-time production monitoring with MES 4.0

Idle / breakdown reason selection from the machine screen and data capture in real time.
Setup / Machining / Inspection and Rework data capture in real time.
Application prompt to enter reason if actual hours are exceeding standard hours.
Smart form to capture actual hours against standard hours for each operation.
Application will have access to drawings, Job card & Machine schedule plan and CNC program.
Operator assistance - Call supervisor / Maintenance person.
Application will have option to take quality input and JH sheet input.
Operator / Supervisor / Shop floor in charge can update the production / process status on a real time basis.

Digital manufacturing solution with MES 4.0

End to End Traceability

Assure that only adequate materials and components enter the final product.
Provide accurate identification, e.g. to avoid mix-up of products which otherwise look alike.
Use of materials on a first-in first-out basis reduces the risk of quality deterioration due to corruptible materials.
To minimize the quality costs and impact of quality problems by identifying, locating and separating defective or potentially defective.
Products from the total product population in internal material flow and from the customer base (e.g. retrofit or recall).
To identify and help fixing the root causes which led to the quality problem.
To enable data for development of supplier quality.
To enable product quality and life cycle management.

Production scheduling and optimization

Real Time Scrap Monitor

Integration of MES 4.0 with ERP and IoT systems

IoT enabled Device for weighing scale to collect real time data.
Identify key production areas with high scrap rates.
Use feedback loops to continuously optimize scrap management processes.
Train staff on using the dashboard and optimizing machine settings for scrap reduction.
Set goals for scrap reduction and recycling targets.
Visual displays of the total scrap generated, categorized by type and source.
Alerts and notifications for scrap exceeding predefined thresholds.
Reports on scrap reduction goals, trends, and recycling percentages.
Predictive indicators of future scrap production based on production schedule and historical data.

Dispatch Management System

Generating QR code / Barcode based on contract / PO part list.
Grouping part number based on assembly and box.
Barcode / QR code scanning while boxing to ensure that no parts are misplaced.
Only after getting clearance from the assembly and quality department confirmation system will allow scheduling dispatch to the customer.
System will take all the parts / assemblies photos in the box to maintain the records.
System will connect the account department to raise the required bill to complete the process.
System will note the SFG GRN & schedule dispatch for the SFG vendor process.
System will complete the SFG vendor process upon receiving material from the vendor by inwarding stock with the same GRN number.
Any delay in the dispatch process delayed notification will be displayed on the dashboard.

Automated quality control and reporting

Maintenance & Asset Management

Analytics dashboard for manufacturing operations

Preventive Maintenance: Scheduled maintenance tasks based on predefined intervals to reduce unexpected failures.
Predictive Maintenance: AI-driven failure predictions using historical data and machine learning models.
Condition - Based Maintenance: Real-time monitoring of equipment conditions using IoT sensors and alerts.
Asset Registration: Maintain a centralized database of all equipment and machinery.
Lifecycle Management: Track assets from acquisition to decommissioning.
Maintenance History: Store and analyze past maintenance records for informed decision-making.
Inventory Control: Manage spare parts and consumables to ensure timely availability.
Downtime Tracking: Monitor and record equipment downtime for trend analysis and root cause identification.
Automated Scheduling: AI-driven scheduling of preventive, predictive, and condition-based maintenance.
Resource Allocation: Assign maintenance tasks to appropriate personnel and manage workforce availability.
Calendar & Notifications: Integrated calendar with automated alerts and notifications for upcoming maintenance activities.
Historical Analysis: Generate reports on past downtime events to improve future scheduling and resource planning.
Integration with Production Systems: Sync with manufacturing and operations systems to align maintenance with production cycles.
AMC & Certification Management: Automated tracking of Annual Maintenance Contracts (AMC) and certification compliance.
Renewal Reminders: Automated alerts for upcoming contract renewals and expirations.
Certification Compliance: Monitor and manage industry certifications and regulatory compliance.
MTTF & MTBF Calculation: Automated calculation of Mean Time to Failure (MTTF) and Mean Time Between Failures (MTBF) for improved reliability analysis.

Quality Control

Raw Material Inspection: Verify raw material quality before production to prevent defects at the source.
In-Process Quality Checks: Conduct real-time quality inspections during manufacturing to detect and rectify defects.
Defect Tracking & Analysis: Implement automated systems to track defects and identify root causes for corrective actions.
Statistical Process Control (SPC): Utilize SPC techniques to monitor and control production quality.
Compliance Testing: Ensure all products meet industry regulations and safety standards before dispatch.

Increase production efficiency with MES 4.0.

Digital Checklist

Reduce downtime with predictive maintenance

Reduce Paperwork & Errors - Eliminate manual tracking with a digital, cloud-based platform.
Improve Compliance & Safety - Stay on top of industry regulations with audit-ready logs.
Enhance Productivity - Assign, monitor, and complete tasks in real-time.
Data - Driven Decision Making - Gain valuable insights with reports and analytics.
Work Anytime, Anywhere - Offline mode ensures uninterrupted operations.
User - Friendly Interface - Simple, intuitive design for easy adoption.
Role - Based Access Control - Secure access with different user permissions.
Real - Time Progress Tracking - Monitor checklist completion instantly.
Automated Notifications & Alerts - Never miss a deadline.
Cloud & Mobile Integration - Access your checklists from any device.
Audit Trail & Reports - Maintain records for compliance and transparency.
Customizable Checklists - Adapt to any industry needs.