2. Top Floor - ERP
Shop Floor - DAS
Information to the shop
floor is provided
electronically in real-
time without using any
printed documents
MES
0
1
0
1
Information is acquired from
the shop floor electronically
in real-time, eliminating the
need to write down and
maintain the hard copy
What is Paperless Factory

3. Why Paperless Factory
Reduces or eliminates errors due to outdated
paperwork, data entry errors and illegible instructions &
drawings
Better utilisation of time
Improve productivity by …
• analyzing the root cause for stoppages and taking
necessary corrective actions
• reducing scrap/rejections by analyzing root cause for
rejections and taking necessary corrective actions
• Improving machine availability by machine health
monitoring
Improve process control by correlating process
parameter with the rejection and dimensional variations
True product costing due to the accurate labor and
machine hour booking
Cost saving
with ROI
between 1
to 2 years

4. How the Paperless Factory
concept works

5. Operator arrives at the machine

6. Swipes his id card

7. Preventive maintenance check list is displayed for the
operator to check and confirm

8. Operator selects the work order by scanning or RFID

9. Control plan, instructions, drawings, videos, materials
including tools & dies, process parameters and online
inspection details can be viewed by the operator for the
selected product and process

10. Operator can load the tool & dies required on the machine for
tracking the quantity produced

11. Operator can load the material on the machine for
consumption or can record the consumption as and when
required

12. Operator starts and stops the production as required
Start date & time
10-May-2002 10:10:00
Stop date & time
10-May-2002 10:10:05

13. If the operator stops and restart the machine for any reason,
he will be prompted to enter the reason for stoppages

14. Gauges and measuring instruments can be interfaced
with the Kiosk/HMI
During the production, operator is prompted to inspect
dimensions based on predefined frequency
Online run chart and process capability is displayed on
the HMI

15. Vision inspection camera can be interfaced with the
Kiosk/HMI at any stage of manufacturing or inspection

16. Operator can enter rejections/scrap with reasons

17. Operator is prompted to enter process parameter
based on predefined frequency

18. Operator can request for help and report breakdown
using the HMI

19. Operator can stop the production, confirm the quantity
produced and unload the job / work order when completed

20. The machine and process parameters along with
quantity produced and rejected / scraped can also be
captured directly from the machines using analog /
digital IO’s and data logger
010101

21. Electronic weighbridge or a weighing scale can be
interfaced with the kiosk for capturing the weight.

22. Kiosk/HMI can be used with storage system for identifying
stored material or locating free space for storage.

23. Existing Installation of 17” floor standing Kiosks

24. The solution
Software
• IcSoft – Product Engineering / Process Document, Historian
(Production Data Warehouse), Operator Interface, Data
Logger & Report Server (Auto emailing of reports and alerts)
• MSSQL – Database
Hardware
• 7”, 17” or 19” Machine mounted, floor standing or table top
Kiosk with RFID and barcode reader
• Data Logger – Device to capture data from IO’s and PLC’s
Services
• Installation of hardware and software, Training & Report
customisation with BI

25. Thank you and please contact us if you have any
queries
Website: www.itspl.com
Contact details:
Vijay Singh
Email: vijaysingh@itspl.com
Phone: +91 – 9341971695
+91 – 7026617295
Website: www.incastconsultancy.com
Contact details:
Stephen Barnett
Email: barnincast@yahoo.com
Phone: +44 (0) 7918699577,
+36 30 537 0864