
Solution Modules
SmartFactory™
Harnessing, extending and delivering on the power of advanced technology to manufacturers worldwide
Comprehensive Operational Control for Manufacturing
Hover over the area you’re interested in to explore the most powerful, versatile, and scalable smart manufacturing solutions available.

MES & Shop Floor Control Solutions
Manufacturing Execution and Shop Floor Control is SmartFactory ‘Base’ module. MES enables all Production Reporting capabilities: work order quantity produced, material usage (controlled items included), component waste, downtime, labor usage and production notes.
MES links to Add-On modules to expanded shop floor control functionality such as label printing, quality and inspections or quality management, connected worker for expanded labor reporting, machine integration, eBR, product or process compliance, etc.
When integrating to an ERP system, MES activates automated integration to and from the ERP system of record to ensure timely and accurate transactional reporting, always making sure your ERP is synchronized with the shop floor execution activities.


Benefits
Improved Operating Effectiveness, Productivity, Resource Utilization, Customer Service, Profitability and Reduced Manufacturing Costs to Produced
Machine Monitoring Solutions
Machine Monitoring is an Add-On module that enables automated machine or edge device connectivity via OPC, MQTT, or Node-RED.
Machine monitoring allows data to be automatically collected from the machine PLC data tag(s) or Edge Devices to improve operational efficiency and awareness.
Machine Monitoring provides for a ‘man-in-loop’ process to ensure accurate machine data of production counts, process variables, and downtime events, etc.


Benefits
Improved Efficiency and Utilization. Reduced Downtime and Process Variation
Quality Management Solutions
Quality and Inspection Management (QMS) is an Add-On Module that enables the conversion of your paper-based quality and inspection events to digital records. Easily create new Inspection record to capture your manufacturing process attributes to ensure compliance to your SOP’s or regulatory requirements.
Includes the Inspection Builder (create), Inspection Manager (assign Inspections and priorities), and Inspection Reporting interfaces. Quality Reporting supports dual signatures: Inspector (which may be an operator, Inspector, etc.) and a Reviewer.


Benefits
Improved Quality, Material Yield and First Pass Yield. Improve QA resources productivity with a digital QA process.
Compliance and CAPA Solutions
Compliance and CAPA (Corrective and Preventive Actions) is an Add-On module that supports Regulatory Requirements (i.e. 21 CFR, Part 11, SQF, GMP, etc.) by enabling the QC Release processes for PO Receipt, In-Process Inspection, Item Fulfillment or Transfer Orders. All compliance and inspection related data can be validated and is maintained in an immutable record structure to support efficient Audit capability. eSignature functionality included.
CAPA augments the Quality and Compliance Management approach to identify, investigate, and address issues with products, processes, or systems. CAPA is a critical component of a regulated industry’s QMS, and is essential for ensuring product quality, regulatory compliance, and continuous improvement.




Benefits
Improve overall Product and Process Compliance reducing overall costs of compliance.
eBR and Kitting Solutions
eBR (Electronic Batch Record Management) and Kitting is an Add-On module designed to support Batch or Process processes. eBR enables a traceable lot record for each batch produced against a parent work order, to include material usage (lot controlled), and quantity produced to ensure compliance to the recipe or formulation. When coupled with our QMS module, additional compliance information, such as deviations or critical process properties, is maintained for each batch record as well as e-Signature capabilities when using the Regulated Industries Account.
A critical element of eBR is Kitting. Kitting enables lot-controlled minor or hand-weighed ingredients to be prepared into a lot control Kit. The Kit is bar-coded to support easy dispensing and traceability into the production batch. Kitting occurs in advance of the batching operations.
All eBR and Kitting information is maintained in a Digital Batch History Record and can be used for compliance audits or forward / backward lot traceability.
Benefits
Improved batch management results in higher product compliance, batch efficiency and lower costs per batch. Improve batch traceability assist in product compliance and lot traceability.




Connected Worker Solutions
Connected Worker is an Add-On module designed to provide manufacturers enhanced Labor Reporting functionality. By Work Order at the Routing and Operation Step level an Operator can dynamically clock in and out of production run(s) to record actual labor time for improved labor utilization and costs.
Benefits
Improves labor productivity reducing labor costs per unit produced.


Note: Connected Worker is not designed to be a Time & Attendance solution or integrate with payroll systems.
Production Management Solutions
Production Management is included with our base MES module and enables Planners or Supervisors the ability to prioritize or group Work Orders to ensure an optimized Shop Floor sequence. The Production Management module is designed to monitor In-Process Work Orders and evaluate Firm Planned and Released Work Orders within a 3 – 5 day planning horizon. The output document is a Dispatch List for each Work Center and integrates seamlessly to the MES module.
Production Management also supports Grouped Work Orders. The Planner or Supervisor is able to combine multiple Work Orders running concurrently on the same Work Center (slitting, multiple dies or mold inserts) as a ‘Parent Work Order’ so the operator can enter only one Production Count to account for all ‘Child Work Orders.’


Benefits
Improves production order sequencing reduces product changeover / setup costs lower overall conversion costs. Also improves customer service and on-time delivery.
Finite Scheduling Solutions
The SmartFactory Scheduler is a powerful, cloud-based finite scheduling solution that optimizes manufacturing work orders into a sequenced production schedule to improve production costs, resource utilization, and service levels. Designed to address the needs of modern manufacturing operations, it combines cutting-edge optimization algorithms, cloud scalability, and an intuitive planning dashboard. SmartFactory Scheduler integrates seamlessly with NetSuite or your ERP system or can function as a standalone planning solution.
SmartFactory Scheduler leverages a high-level algorithmic framework to help find solutions to manufacturing production scheduling problems. By using sophisticated AI algorithms and constraint-based parameters, the SmartFactory Scheduler optimizes the schedules tailored to your operational needs.
Benefits
- Improved resource utilization; equipment, labor, and tooling.
- Reduced delays, work-in-progress costs, and non-value-added time due to poor coordination
- Increased operating efficiency, leading to higher customer service levels and on-time delivery
- Lowered Cost-to-Produce




Materials Management Solutions
Materials and Inventory Management is an integral capability embedded throughout SmartFactory MES. Tracking material consumption (controlled or backflush), component waste, inventory and WIP movement, and related transactions are essential for accurate inventory and material costing. Material Management is designed to reinforce a manufacturer’s material staging discipline and visibility.
When utilized with ERP connectivity and Bin Management, BOMs are automatically mapped to SmartFactory and associated to the appropriate Routing, Operation Step and Work Center. This supports real-time material validation, actual consumption, WIP tracking, and all associated inventory detail transactions to ensure accurate and timely reporting and General Ledger impact.


Benefits
Improves Inventory accuracy and visibility of raw, WIP and Finish Goods leading to improved inventory turns, material yields, reduced stock-outs and downtime waiting on material resulting in overall lower material costs per unit.
ERP Connection Solutions
ERP Connectivity and Integration is one of SmartFactory greatest benefit to an organization. The ability to harmonize your actual MES / Shop Floor activities with your ERP system of record is essential in today’s digital business world. SmartFactory is designed to easily and automatically connect to your ERP or function as a standalone solution. Your choice!
SmartFactory ERP connectivity is bi-directional and automatically maps the relevant Item, BOM, Bin, Work Order, Routing, Work Center and related transactional and operational data to ensure your ERP and MES are synchronized.


Ready to Go ERP Connections
Reporting & Analytics Solutions
While MES applications serve a valuable role in defining, directing, and documenting factory activities, the big payoff is about the data generated along the way and how that information can be used to answer crucial questions and solve the problems that are encounted every day.
SmartFactory feeds two important types of reporting and analytics:
- Operational reporting provides a snapshot of what’s currently happening in manufacturing. It shows the state of things, right now
- Historical reporting shows trends over time, making it possible to see whether conditions in the factory are getting better or worse
In the end manufacturing leaders have actionable insights to help the staff proactively spot problems, identify root causes, and provide options for solutions.


Benefits
Deep insight into manufacturing processes, production, labor productivity, and overall effectiveness, identification of bottlenecks, and better cost control while heading off problems before they happen.
JOIN OUR MAILING LIST —
© 2016-2024, Providence Consulting Group, LTD. All rights reserved. All logos, trademarks and trade names are property of their respective owners.