Product Overview

FLEX-OS 'Open' Integration Platform

Integration Platform SoftSolutions' FLEX-OS runs mission critical Manufacturing Execution Systems at plants ranging from Volvo Trucks to Sheridan Books. FLEX manages the rules between real-time production events from Operations and front-office Sales Scheduling and Estimating systems to keep management information flowing with minimal hassle.

FLEX-OS is designed to promote rapid integration across 3rd party systems using 'open' industry standards such as JDF/JMF in the print sector and ISA-95 across general industry applications.

FLEX-OS provides a robust messaging system with over 30 "data connectors" for a wide range of information sources such as:

Front Office Sales systems such as MS Dynamics, JD Edwards, SAP, and PeachTree
Direct Machine Interface (DMI) from partner PLC controls to legacy equipment
Bar code scanners for quick and easy material tracking and data entry
Weigh Scales for measuring and counting products

FLEX-OS also generates Alerts & Notifies when events trigger preset conditions such as an extended downtime or long setup that exceed Performance Standards defined by Standard Operating Procedures or Job Targets from the existing ERP/MIS Estimating system.

FLEX-PCS reduce data entry time - increase data accuracy

Timesheet Tools Employees across a wide spectrum of industrial equipment use the FLEX-PCS Production Control System everyday to automatically capture accurate Job Costing data and Performance Metrics during their production shift.

Most customers configure FLEX-PCS to collect job data directly from equipment, which increases Job Costing accuracy while reducing operator paperwork and data collection time - often by more than 50%.

FLEX-PCS provides a Labor & Material tracking system with a range of value-added features for enabling higher Workforce Performance, such as:

Clearly communicate Workforce expectations with electronic Work Standards
Automatically capture real-time Workforce performance metrics directly from machines
Provide real-time performance feedback based upon the defined Work Standards

FLEX-PCS frees up skilled workers to focus on running more production. At the same time, it automatically captures more accuract performance data in the context of your specific Work Standards, enabling more effective performance management.

FLEX-Data Dashboards communicate Workforce results in real-time

Digital Dashboard Whereas FLEX-Timesheets automate the communication of Work Standards and the collection of Workforce results, FLEX-Dashboards provide the visualization tools that will enable faster response to performance opportunities.

FLEX-Dashboards are browser-based solutions; they can run on virtually any PC platform, from Linux to MS Windows. Our goal is to enable clients to access their key performance data as cost-effectively as possible.

FLEX-Dashboards & Scorecards provide powerful visualization tools that include:

Real-time performance gauges, bar-charts, and trend-lines
Performance Scorecards based upon machine, shift, day, month, quarter, etc.
Drill-down capabilities to easily access detailed performance information

FLEX-Dashboards and web-based Scorecards provide a highly cost-effective means of distributing the real-time performance metrics captured within the FLEX-Timesheet module.

FLEX-WIP Tracker automates real-time Material tracking

WIPTracker FLEX-WIP Tracker includes algorithms for advanced Lot tracking, including detailed genealogy reporting. This type of information is critical in cases of product recalls where the span of customers effected can be significant if genealogy information is not available.

Clients such as Volvo Trucks North America use the FLEX-WIP Tracker to gain real-time visibility on each cab train being routed through the BIW and Paint process. Massimo Coffee & Tea utilize FLEX to track coffee beans from the receiving process at the dock, into blending and roasting. Detailed genealogy records are maintained by FLEX through each step of the manufacturing process.

FLEX-WIP Tracker provides a robust genealogy tracking solution with features such as:

Lot tracking from parent to child at each transforming process step on the route
Easy to use search tools to quickly find real-time Lot status and WIP levels across the shop floor
Ability to propagate a forward genealogy based upon a Parent LotID to find all children or a backward report based upon a child lot
Advanced tools to find and address 'orphan lots' that may occur due to data collection issues from shop floor equipment

FLEX-WIP Tracker and genealogy software provides a powerful tool for both product recalls and for analyzing vendors for quality issues that may arise over time.

FLEX-Scales Management

Scale GUI SoftSolutions' offers a 'pre-integrated' Scales Management solution built upon proven FLEX components. This application is ideal for integrating your existing production weigh scales directly into your front-office billing process.

FLEX-Scales Management software can be easy integrated with almost any scale indicator that supports a RS-232 serial interface or equivalent, such as Avery Weigh-Tronix, Mettler Toledo, and GSE Scale Indicators.

Clients such as Sheridan Book utilize the FLEX Scales module for accurately counting waste product or adjusting good counts for recovered units in their press room. Cycle Systems utilizes FLEX to automate their peddler process at their recycling scales and automate the feed of billing data to their front-office RECY software.

Our integrated Scales Management software offers several advantages over traditional, manual processes, including:

An easy to use Graphical User interface with color-coded pushbuttons to help new workers quickly get up to speed with minimal errors when recording Gross, Tare and Net amounts from the scale
Data integration options to connect your scales process directly into your customer billing process, once again minimizing any human error and automating out manual paperwork
Options to integrate easily with other popular tools such as MS Office, barcode scanners, MS Windows printers, marquee display units, and security camera units

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Product Focus

SoftSolutions' Flex-PCS is a full Production Control Solution that provides Real-time visibility between front office Sales planning systems and shop floor Operations. Flex-PCS provides decision makers with real-time updates throughout the day on how "Production to Plan" is going and where problems are developing right now.

Over the past decade, SoftSolutions developers and engineers have worked closely with manufacturing operations teams to understand the types of issues that impact your daily production schedule. The single most important need for most decision makers is having accurate, timely visibility on their Production Plan for the shift, the day, the week. Flex-PCS closes the loop between front-office planning and shop-floor execution (budget to actual).

Our Services group can rapidly customize and deploy these advanced data integration solutions within a matter of days and with minimum disruption to live production systems.

Data Automation

Given the high cost of today's skilled workers and the relatively low cost of data collection hardware and software options, there is little if any justification to continue using paper and pencil to manually collect data.

FLEX provides 'data connectors'to devices ranging from PLCs, SCADA systems, barcode scanners, security cameras and weigh scales to database systems and front office accounting systems. This enables us to help our clients fully automate the flow of information into and out of various information sources with virtually zero human involvement.

Data Integration

Once data is collected using automated tools such as barcode scanners and RFID, it needs to be reliably processed and stored in the correct destination. Likewise, critical job information from planning systems such as SAP, MS Dynamics, and Oracle need to be downloaded reliably to the operator's local web-browser to capture the information in the proper context of the customer job.

FLEX takes care of these mission critical integration functions 24X7, thousands of times each week at client sites ranging from book printing plants to cosmetic packaging companies to automotive manufacturing to food & beverage companies.

Communication

Over the years, SoftSolutions has gained a reputation of providing user-friendly, highly functional operator screens, scorecards, dashboards, and reports that help clients take action on their business metrics. Fancy names such as Business Intelligence, Business Activity Monitoring, and Performance Management continue to come and go. At the end of the day, we see significant value created for clients by simply providing more effective communications tools.

One key area of expertise at SoftSolutions is Real-Time Communications, whether it be real-time Job Scores on a web-page or automated e-mail Alerts & Notification, helping clients respond faster with better information is a fundamental component of SoftSolutions' value to our clients.

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