CATS Modules

EDI import

Automatic import of client orders using EDI files over various communication protocols.

  • Automatic processing of client part orders using various EDI formats
  • Multiple transfer protocols are supported for file transfer and also custom parsing algorithms can be easily implemented.

EDI export

Generate EDI files and transfer them to suppliers and clients

  • Generation for EDI files to notify client when deliveries are made.
  • Multiple types of file transfer protocols are supported: ftp, sftp, samba shares, email, http post, etc.

Warehouse receiving

Manage receiving process by tracking receipts, scanning and labeling all incoming goods.

  • Manage receiving processing in multiple modes ( manual receiving, EDI receiving, scheduled receiving )
  • Match received quantitites with receipt content created in advance
  • Print receipt labels to identify all storage untis with unique serial numbers

Part amount decanting

Dividing large quantities of material into smaller ones that are used for feeding in order to track lot data at a high resolution and efficiency

  • Divide storage unit amounts in smaller quantities identified with unique serial numbers
  • Printing of labels for each decanted storage unit amount

Stock movements

Track the assingment of serialized items across the shop floor to a spcific identified location.

  • Assign item  to location by scanning unique serial numbers to part and location
  • Track history of movements
  • Define custom rules and flows for parts location assignment
  • Visually represent location storage status

Incoming material check

Track received materials in free pass state based on custom rules to ensure that suspicious or untrusted materials are checked before moving them to the raw material area.

  • Define part based rules for specifc part lot inspections frequency
  • All storage units with parts the are in inspection mode will receive the "check" status imediately after reception
  • Parts that are makerd to be in check status will not be allowed to be used on production lines

 

Inventorying

Perform inventory sessions by scanning all existing storage units and parts found on location and report them against the current database records

  • Mobile applications support for shop floor inventorying process ( Example: Android mobile scanners, Smart phones, etc. )
  • Automated reporting feature that results in a summary of missing part amounts and part amounts that do not exist in the database
  • Generate scrap declaration and negative inventory costs

Warehouse shipping

Prepare and scan storage units for shipment, validate the prepared containers and manage the deliveries at a high detail

  • Perform shipments in multiple modes ( manual, EDI based, Scheduled shipping )
  • Mobile operation support from device like Android mobile scanners or Smart phones
  • Shipping containers marriage and seal validation
  • Validate shipment storage units assignment in a FIFO based sequence

Production declaration

Declare production data to external software systems. Example: backflush, storage locations with their content or scrapped part amounts.

  • Declare production directly to ERP external database
  • Generate EDI files to be transferred for later processing by external software
  • Provide modern communication protocols for external software usage that expose internal data records link production, scrap or process related informations ( rest api, message broker, web sockets )

Production line

Efficiently represent the real environment production flow as production lines and operations and manage the way that they behave from the simplest up to the most complex type of operation that a manufacturing environment can have

  • Produce based on line operation assigned part numbers using sources like production scheduling, manual set-up or automated selection based on assembly serial
  • Line material loading based on BOM
  • Automated serial flow validation based on multi level BOM
  • Operators and roles tracking
  • Track downtime 
  • Configurable operation steps 
  • History of processed parts
  •  Preview of last printed label

Downtime management

Track and manage downtime events that happen on shop floor operations based on predefined list of issues

  • Operators can open operation downtime event by selecting a downtime reason
  • Downtime events can be processed by specific users depending on their assigned roles
  • Closed downtimes have to be validated for permanent closure
  • All downtime durations are compared with the downtime data record for later reports
  • Real time visual indicators for shop floor downtime 

Machine values acquisition

Track production devices and industrial machinery process related values using the values for validation of produced parts, subsequent part measurements and other various analytics

  • After each end of cycle CATS software will retrieve the process related values and store them associated to the process cycle record
  • The values are stored in a nosql database for later analytics usage purposes

Test dispatch

Deploy parts for testing to ensure constant compliance by creating dispatch rules based on customer requirement
  • Dispatch part for testing based on custom defined rules
  • Block shipping of containers based on testing groups
  • Track testing results linked to part production records

Change management

Track all changes made related to the part or process enviroment that later can be reported against other events that occur in the production flow ( issues, setup change, revision change, maintenance interventions, IT interventions, etc. )
  • Track part revision change and the time from when the revision was activate in the production line
  • Link various events to a specific type of change entry ( downtime intervention, maintenance,setup change etc. )

Preventive maintenance

Schedule preventive maintenance events to make sure that hardware spare parts are checked periodically and consumables are replaced based requirements

  • Schedule maintenance tasks to be performed on process equipment
  • Define equipment consumables that need to be replaced periodically

Spare parts

Track the stock levels of spare parts and send notifications when certain levels are reached

  • Define spare parts stock levels 
  • Send automatic notifications where spare parts stock levels were reached

Process machine link

Align line process operation CATS software with the process machine using a direct connenction where software and machine work as one unit.

  • CATS application tells the process machine what part is produced so that the machine will select the corresponding setup
  • Machine waits for CATS signal in order to start the process
  • After the start was given CATS software will monitor the machine output until the end of process signal is received and check the success status

Locations

Identify areas in the manufacturing environment in a hierachical structure used to track the position of a serial

  • Represent visually the plan layout to easily identify the position of an item
  • Reduce the human effort by helping with visual indicators
  • Optimize space usage in the plant

Issue management

Tracking of issues that occur in production by assigning them to exiting part serials or lots.

  • Track issue as traceability record with the possibility of linking various records to it ( part, line operation, storage units, process device, etc. )
  • Track issue specific documents ( 5Why, 8D, etc. ) as data records to file attachments
  • Track issue recurrence
  • Generation of lesson learned 

Rework of parts

Tracking the rework process at a high resolution by recording the rework actions and the materials used during the process

  • Serial based tracing of reworked parts
  • Trace LOT of materials used during rework and of the scrapped amounts
  • Recovering of reusable components in case of disassembling
  • Part transforming

Production feeding

Feed production operations with material in a managed way

  • Validate storage unit serial on production line to be valid for FIFO loading
  • Allocate KANBAN cards to assure material replenishment
  • Mobile applications that manage the movement of material from storage to production line

Scrap

Declare scrap and block amounts from usage in production

  • Manage scrap declaration with standalone and mobile operations
  • Block scrapped amounts from usage in production or shipments
  • Generate scrap costs

Packaging

Manage packaging of parts using uniquely identified amounts

  • Multi-level packaging system in which parts can be packed into containers that can be packed in other containers ( palletization )
  • Unique identification of packed part amounts
  • Label packages with custom designed layouts

Schedule production

Schedule production of part amounts and assign them to the production line operations

  • Generate production part amoutns based on customer orders and assign them to the production lines
  • Use KANBAN system to control the flow of produced amounts
  • Manage production using methods like build to order, inventory or forecast

Quality wall

Validate critical products by passing them thru a quality check wall before they are shipped

  • Dedicate application used to change the state of parts that must be validated to complete their state
  • Assign a seal with a unique serial number to a storage unit that is complete and validated before shipment to ensure the integrityof the packed goods.