AquiWeb.

Machine times, operator times and production order progress. Equipment data acquired over IIoT and OPC UA; manual entry from PCs and tablets where there is nothing to read. Equipment states and process parameters, direct and indirect operator hours, order management and activities.

OEE and overall equipment performance calculated to the AFNOR NF E 60-182 definitions, with a Pareto of non-performance causes and period-by-period dashboards. Which definition of OEE you are using turns out to matter enormously the first time two plants compare numbers.

Inspection plans defined and configured against references, production orders, workstations and areas, with inspection frequency, sample size and criticality levels set per check. Multi-plan and multi-order handling, visual alerts on non-compliance, and an interface with drawings, documents and video where an instruction needs showing rather than describing.

SPC control charts with Cp, Cpk and Cpm; measurement instruments connected over USB, RS232, OPC UA or file drop; and a configurable non-conformance workflow that can be raised manually or triggered automatically.

Preventive and corrective maintenance on equipment and tooling, with the periodic plan driven by actual production rather than the calendar. Work launched around production windows, operations declared with their documentation attached, and procedures guided through Aquiguide.

Pareto, MTBF, MTTR and OEE generated automatically. On the operator side, a visual alarm on the machine dashboard when self-maintenance is due, simplified declaration, and a maintenance call by email.

Planning that takes ERP requirements, work in progress and preventive maintenance into the same view. Automatic optimisation under configurable constraints, drag-and-drop adjustment on a Gantt chart, and workload assessed against actual human resource capacity.

Simulation of opening times, placement rules and the impact of maintenance delays. Orders imported and exported against ERP on a defined cycle, with unplanned orders visible and advances or delays flagged before they become a customer conversation.

Electronic document management for the shop floor. Drawings, work orders, tooling sheets and procedures available at the station, split between static documentation attached to a workstation and dynamic documentation that follows the current order, control or machine state.

Version management is the point. The operator sees the current revision because there is no other revision to see.

Step-by-step instructions with a direct link between the current step and the documentation page for it. Manual or automatic validation at each step, timestamped against the operator and the action, and batch entry checked against what was expected.

Printers driven for labels and records, and data acquired from the equipment itself to validate a step. The history of executed procedures also shows where the same operator error keeps recurring, which is usually a training problem rather than a discipline problem.

Batch and serial identification created and recorded, with labels printed for RFID, direct marking or barcode, and consistency checked against the bill of materials. Documentation displayed for each operation as it runs.

Genealogy captures batch, component, raw material, quantity, operator, equipment and incidents. Search by batch, production order or person, upstream and downstream — which is the search you make at eight in the evening when a customer calls.

Receipt orders and lines pulled from ERP, with the person and place of receipt traced, conformity checked through Aquiqual, batches broken down into handling units, and units labelled and assigned to locations.

Real-time stock by location, movement history, customer shipments and supplier returns. Shortage alerts can be triggered back into the ERP rather than discovered at the line.

Water and electricity consumption acquired in real time by machine, cell, zone or workshop, then correlated with what was actually produced. Energy efficiency ratio, energy intensity and energy performance rate derived from the pair.

Alerts on consumption drift relative to the process, which frequently surfaces a mechanical problem before the maintenance system does. Structured for the PDCA cycle an ISO 50001 energy management system asks for.