Reference Projects

 

REFERENCE PROJECTS in INDUSTRY 4.0  
 

 

VESTEL CONSUMER GOODS – METAL PRESS FACTORY  

Project started to manage Metal Press Shop Floor for Vestel Electronics High End Factory. Work orders from planning software received from SAP ME running at the operator stations. We control production machines to ensure proper production for a given work order. MES Screens are used to facilitate desired operator actions to operate on Quality and Maintenance modules. Project reached its goal of maximum OEE and minimum production errors.

 

 

 

 

TOKSAN & AKPRES  AUTOMOTIVE PARTS

Manufacturing Execution System ( MES ) Project implemented for Toksan Bursa and Gebze, Akpres Hendek and Bursa factories of Datatech Holding utilising SAP MII.  Production confirmation, Quality Control and Maintenance Operations managed from MES System which works in an integrated fashion with SAP Production Planning,  SAP Plant Maintenance and SAP Quality Management modules. Android Operator panels, barcode readers and PLC systems were used for data collection from shop floor and production machines.

PANPLAST ( KONYA SUGAR ) PLASTIC PIPES FACTORY

SAP MII is used for Manufacturing Execution Project of Panplast Factory where irrigation pipes are manufactured. Production confirmation is generated automatically with the data collected from production machines and operator interfaces. Production reports and OEE data are reported.

ELIF PLASTIK

EST Enerji worked on the SAP Project of Elif Plastik where Production Management requirements of the factory fullfilled sucessfully. SAP MII Project includes automatic data collection, downtime analysis, confirmation of production orders and management of automatic maintenance activities as well as operators involvement in production. Successful implementation of the first project  led the realization of same project in Elif Plastik’s Egypt Factory.

AKZO NOBEL (MARSHALL PAINT FACTORY)

SAP MII is used to provide an automatic OEE computation for Filling Department of AKZO NOBEL Gebze Plant (Marshall).  Downtime data collected automatically from filling machines and detailed reports provided. Productivity of the system monitored carefully to comply with global AKZO targets. This successful project imitated and extended for other Akzo Plants worldwide.

 
 

 

ARÇELİK BOLU COOKING DEVICES FACTORY

 Quality Control Devices for Electrical Tests were developed. Test data are stored for reporting and quality control in a database. Automatic test application and storage of test data provide significant improvement for the Quality Control Process. Due to novel design of the machines significant price and technical advantages obtained with the configuration.

 

 

FRITOLAY, TARSUS

Fritolay Tarsus saved 30% on water consumption with detailed analysis of their water, electric and gas consumption. Consumption of utilities traced and cost per product is found. Large Andon Panels display target and real consumptions. Central Historian is used to store real time data and generate reports.

   

 

 

 

ÇAYELİ BAKIR – COPPER MINE

Copper Mine is monitored with several SCADA Systems. A Central Historian is used to report details of daily operations. Plant wide operations improvement is achieved from these detailed reports.

 

 

 

ÇELİKORD, Pirelli ,  Izmit

Cable factory automation data stored in a central “Historian”.  Production data from two hundred machine PLC s collected and used for quality control purposes. 

 

BAYER TURK (Gebze)

Central Historian application developed to connect several SCADA systems. Integration interface developed to connect Historian to SAP ERP.

 

TÜRKTIPSAN  PHARMA

Serum Production Facility MES application developed. Production without paper was the target of the project. MES screens embedded in SCADA HMI to avoid different Operator Interfaces.  Integration with SAP ERP is obtained. Packaging Line management and barcode integration is also achieved. It is guranteed to ship correct products to correct customers. 

 

 

FEDERAL ELEKTRİK

Quality Control Test Set connected to ERP for continuous flow of quality data to ERP System. PLC and SCADA systems of the Quality Control line is connected via an interface software.

 

 BORUSAN MAHMUTBEY  PIPE PRODUCTION FACTORY

Pipe machines data collected and transferred to AS/400 for Manufacturing Execution purposes. System is used for Quality Control, Downtime Analysis and Maintenace Management.

 

ASSAN SOĞUK HADDANE  – ALUMINIUM FACTORY COLD ROLLING – Maintenance and OEE Project

ASSAN Aluminium Factory First Cold Rolling Mill Production Management System is developed. Production management functions arranged to simplfy the operator tasks, analyse downtime and and manage maintenance activities. Machine PLC s connected to Kibarpro ERP System. Productivity increased as a result of the project. Relation between machine failure and set points of the machine and their correlation with different types of products observed as a side return of the project. Hence improved business rules observed and implemented.

 

SCM LINE MANAGEMENT (Rimini, Italy)

For EUREKA program project ST. JOSEPH 2000, a demo system is developed. Line Management Software is developed for the demo factory. Demo factory composed of three woodworking machines and a quality control center. EST developed the supervisory line management software responsible of running the line of production. Communication drivers for barcode system automatic trolleys and control PLC s were developed.  Line management software executes the decisions of the Quality Control Center and send panels to packaging, repair or scrap. An optimisor software developed to minimize cutting losses.

 

AETNA (Rimini, Italya)

AETNA developed a demo system for PACK 2000 EUREKA (E!2007) project.  Flexible environmentally friendly packing system utilizing advanced vision technology and recyclable materials project line management software developed. Packages without error is obtained with the integration of PLC, Quality Control and line speed.

 

BRISA SHOP FLOOR PROJECT

BRISA is the largest tire plant in Turkey.  The project was to establish MES layer for full automation of the factory.  EST worked on PLC and SCADA applications for ATOS Origin. More than 500 machines connected to ERP System where PLC set points changed automatically with the given tire recepie. EST continued to give support for the project for five years after startup.