ERP · MES · DIGITAL TWIN · 3D WAREHOUSE · SECTOR ARCHITECTURE

Industries Served & Sequential Shop-Floor Screen Architecture.

We architect shop-floor execution around the real physical flow of the plant — from raw material entry and preparation to main line execution, quality verification and 3D finished-goods warehousing. Select an industry below to inspect its 5-step screen and process workflow.

01 — INDUSTRIAL VERTICALS (6 CORE SECTORS)

Select Your Industry: How Is the Shop Floor Managed End to End?

Each sector card presents the 5 sequential production stages, the operator and supervisor screens used at each stage, and the 3D Digital Twin / 3D Warehouse architecture.

SECTOR 01Heavy Industry & Primary Metallurgy

Iron & Steel · Meltshop and Continuous Casting (CCM)

Step-by-step execution across raw material preparation, Electric Arc Furnace (EAF) / Basic Oxygen Furnace (BOF), Ladle Furnace (LF), Vacuum Degassing (VD) and Continuous Casting Machine (CCM) stations via operator cockpits, quality panels and a 3D Digital Twin.

SHOP-FLOOR PRODUCTION FLOW (5 SEQUENTIAL STAGES)

01Raw Material Preparation, Sintering and Hot Metal / Scrap Charging
02Primary Smelting (Electric Arc Furnace / Converter) and Desulfurization
03Secondary Metallurgy (Ladle Furnace - LF & Vacuum Degassing - VD)
04Continuous Casting Machine (CCM) and Mixed-Grade (Intermix) Casting Management
05Turnover Cooling Bed, Robotic Barcoding and Semi-Finished Billet Yard

5 Core Stations

Sequential Shop-Floor Flow

25+ Field Screens

Operator & Supervisor UI

Live Analysis & 1640°C

Chemical & Thermal Tracking

Heat → Billet

Traceability

Open Shop-Floor Screens & Process Architecture→

SECTOR 02Heavy Industry & Hot Forming

Iron & Steel · Hot Rolling Mill, Reheating Furnace and Wire Rod / Bar Mill

Rolling mill architecture spanning furnace entry camera verification, in-furnace billet thermal mapping, hot rolling stands, cold shear/saw cutting, non-destructive crack testing (NDT), bundling and 3D finished goods warehouse management.

SHOP-FLOOR PRODUCTION FLOW (5 SEQUENTIAL STAGES)

01Billet Selection, Overhead Crane Feeding and Furnace Entry Verification
02Reheating Furnace Walking-Beam Tracking, 3-Zone Thermal Process and Billet Map
03Hot Rolling Mill Line, Main Pulpit Tower and Specific Energy Monitoring
04Cooling Bed, Cold Shear, Abrasive Saw Cutting and Surface/Crack NDT
05Bundling, Strapping, End Painting, Labeling and 3D Finished Goods Warehouse

5 Core Stations

Sequential Shop-Floor Flow

35+ Field Screens

Operator & Report UI

Single-Billet FIFO

Furnace & Mill Tracking

3D Bay & Rack Matrix

Warehouse & Dispatch

Open Shop-Floor Screens & Process Architecture→

SECTOR 03High-Speed Process & Packaging

Fast-Moving Consumer Goods (FMCG) · Hygiene, Personal Care and High-Speed Packaging

Chemical solution/mixer (Drop) batching, FIFO roll/packaging feeding, high-speed filling and converting, centralized Inkjet coding, bulk palletizing and 3D warehouse inventory reconciliation.

SHOP-FLOOR PRODUCTION FLOW (5 SEQUENTIAL STAGES)

01Chemical / Semi-Finished Solution Batching and Mixer (Drop) Process
02Line Setup, Roll / Packaging FIFO Feeding and Sanitation
03High-Speed Production, Filling, Centralized Inkjet Coding and OEE Andon
04Secondary Packaging, Case Packing, Palletizing and Order Completion
05Floor Buffer Stock, Elevator/Conveyor Transfer and 3D Finished Warehouse Putaway

5 Core Stations

Sequential Shop-Floor Flow

40+ Field Screens

Operator & Supervisor UI

12 Lines + 5 Stages

3D Line & Pallet Flow

3D Rack & Batch

Warehouse & FIFO Control

Open Shop-Floor Screens & Process Architecture→

SECTOR 04Continuous Process, LGV & Converting

Paper & Converting · Tissue Paper, Parent Jumbo Roll and Converting Lines

Pulp furnish blending, Paper Machine tambour/parent roll winding, autonomous reel logistics via Laser Guided Vehicles (LGV), converting lines, Statistical Quality Control (SQC) and finished warehouse operations.

SHOP-FLOOR PRODUCTION FLOW (5 SEQUENTIAL STAGES)

01Pulp Raw Material Preparation, Furnish Blend Recipe and Chemical Dosing
02Paper Machine — Tambour (Parent/Jumbo Roll) Winding and Rewinder Slitting
03Reel Grouping and LGV (Laser Guided Vehicle) Autonomous Logistics
04Converting Lines (Perforation, Embossing, Winding, Log Saw and Packaging)
05Palletizing, Forklift Operations and Finished Goods Warehouse Management

5 Core Stations

Sequential Shop-Floor Flow

45+ Field Screens

Operator & Supervisor UI

LGV Integration

Autonomous Intralogistics

SQC, UD & OEE

Quality & Efficiency

Open Shop-Floor Screens & Process Architecture→

SECTOR 05Assembly Lines & Serial Production

Discrete Manufacturing · Home Appliances, Electromechanical and Automotive Tier-1

Unit-level Shop Floor Control (SFC) assembly management, barcode component interlocks, smart torque/test rig integration and line-side material replenishment architecture.

SHOP-FLOOR PRODUCTION FLOW (5 SEQUENTIAL STAGES)

01Press Shop, Metal Stamping and Sub-Assembly Cell Production
02Body Preparation, Surface Treatment and Paint / Enamel Line Tracking
03Multi-Station Assembly Lines, Barcode Component Validation and Poka-Yoke
04Electrical Safety, Performance Test Booths and Closed-Loop Rework Routing
05As-Built Unit Genealogy, Rating Plate Printing, Packing and Dispatch

5 Core Stations

Sequential Shop-Floor Flow

Unit Serial No (SFC)

Traceability Unit

Real-Time Interlock

Error Proofing (Poka-Yoke)

Standard POD Template

Multi-Plant Architecture

Open Shop-Floor Screens & Process Architecture→

SECTOR 06Electronics & High-Granularity Traceability

Electronics, Surface-Mount (SMD) PCBA and Precision Device Manufacturing

Electronic component reel verification, Moisture Sensitive Device (MSD) floor-life tracking, SMD pick-and-place, AOI/functional testing, firmware loading and full As-Built Genealogy.

SHOP-FLOOR PRODUCTION FLOW (5 SEQUENTIAL STAGES)

01SMD Component Preparation, Reel-to-Feeder Verification and MSD Floor-Life Tracking
02Laser PCB Marking, Solder Paste Printing, SMD Placement and Reflow Oven
03Automated Optical Inspection (AOI / X-Ray) and Visual Defect Classification
04In-Circuit Test (ICT), Firmware Flashing and Functional Calibration
05Final Box-Build Device Assembly, Electronic As-Built Genealogy and Packing

5 Core Stations

Sequential Shop-Floor Flow

Reel ID & MSD

Component Control

AOI · ICT · FCT

Test & Diagnostics

Reel → Final Device

Genealogy Depth

Open Shop-Floor Screens & Process Architecture→

02 — HOW THE SHOP FLOOR IS MANAGED · SCREEN & PROCESS GUIDE

Sequential Shop-Floor Screens Across Industrial Sectors

Across every manufacturing plant, shop-floor operations are governed through four screen layers: Operator Cockpits (POD), Shift Supervisor & Control Dashboards, Quality & Laboratory Screens, and 3D Digital Twin / 3D Warehouse Views.

SECTOR 01Heavy Industry & Primary Metallurgy

Iron & Steel · Meltshop and Continuous Casting (CCM)

In meltshop facilities, production starts with charging scrap baskets or torpedo-car hot metal from the blast furnace, reaches target chemical composition across primary smelting and secondary metallurgy stations, and solidifies into semi-finished billets at the continuous casting machine (CCM). The shop-floor architecture tracks each individual Heat across all stations, uniting Level-2 (L2) automation, spectrometer laboratory systems, operator panels (POD) and a 3D Meltshop Digital Twin on a single data backbone.

Sector Detail Page →

STEP 01

Raw Material Preparation, Sintering and Hot Metal / Scrap Charging

Coordinates weighing and pouring of torpedo-car hot metal from the blast furnace in integrated plants, or layered magnetic crane loading of graded scrap into charging buckets in electric arc furnace plants.

1. Operator Screens (POD)

Scrap Bucket Preparation and Layered Charge Consumption Screen
Torpedo Car Weighing and Pouring Operator Screen
Sinter Production and Raw Material Weighbridge Consumption Screen

2. Shift Supervisor & Control

Order Sequencing and Heat Scheduling Cockpit
Raw Material Inventory and Charge Queue Monitor

3. Quality & Laboratory

Incoming Raw Material and Sinter Chemical Analysis Screen

4. 3D Digital Twin & Warehouse

3D Scrap Yard and Bucket Charging Digital Twin (Overhead magnet crane, scrap bays and live charging bucket telemetry)

STEP 02

Primary Smelting (Electric Arc Furnace / Converter) and Desulfurization

Tracks hot metal desulfurization and converter blowing or scrap melting in the Electric Arc Furnace (EAF), recording electrical energy, oxygen, carbon, lime and alloy additions through tapping into the steel ladle.

1. Operator Screens (POD)

Electric Arc Furnace (EAF) / Converter Heat Operator Screen
Desulfurization Operation and Reagent Consumption Screen
Primary Alloy and Consumable Addition Confirmation Screen

2. Shift Supervisor & Control

Meltshop Order and Active Heat Management Screen
Primary Smelting Daily Production and Tap-to-Tap Report
Automated / Manual Downtime and Breakdown Logging Panel

3. Quality & Laboratory

Spectrometer Real-Time Chemical Analysis Monitor (13 Elements + Carbon Equivalent Min/Max Tolerance Check)

4. 3D Digital Twin & Warehouse

3D Electric Arc Furnace (EAF) Digital Twin (Tilting furnace shell, electrodes, ladle transfer car and 1640°C FLIR Thermal Heat Map mode)

STEP 03

Secondary Metallurgy (Ladle Furnace - LF & Vacuum Degassing - VD)

Manages ladle heating to target casting temperature in the Ladle Furnace (LF), argon stirring, ferro-alloy bin dosing and cored wire feeding for final chemistry trim, plus Vacuum Degassing (VD) for specialty steel grades.

1. Operator Screens (POD)

Ladle Furnace (LF) and Vacuum Degassing (VD) Process Tracking Screen
Ferro-Alloy Bin and Cored Wire Feeding Consumption Screen
Ladle Preparation, Refractory Life and Casting Ladle Tracking Screen

2. Shift Supervisor & Control

Ladle Furnace Daily Production and Cycle Time Report
Meltshop Master Overview and Station Pacing Panel

3. Quality & Laboratory

Secondary Metallurgy Sample and Quality Result Screen
Target Steel Grade Recipe and Temperature Deviation Alert Screen

4. 3D Digital Twin & Warehouse

3D Ladle Furnace (LF), Vacuum (VD) and Ladle/Tundish Preheating Twin (Alloy hoppers, vacuum vessel and burner preheating stands)

STEP 04

Continuous Casting Machine (CCM) and Mixed-Grade (Intermix) Casting Management

Controls ladle opening on the rotary turret into the tundish, solidification through water-cooled molds across 4 casting strands, intermix zone calculation during sequence casting of different grades, and oxy-fuel torch cutting.

1. Operator Screens (POD)

Continuous Casting (CCM) Operator Cockpit and Heat Detail Screen
Mixed-Grade (Intermix) Casting Tracking and Transition Zone Segregation Screen
Continuous Casting Production Confirmation and Head/Tail Crop Scrap Screen

2. Shift Supervisor & Control

Continuous Casting Efficiency and KPI Dashboard
Sequence Casting Continuity (Tundish / Ladle Sequence) Monitor
Continuous Casting Daily and Monthly Output Report

3. Quality & Laboratory

Heat-Based Quality Disposition and Billet Grade Classification Screen

4. 3D Digital Twin & Warehouse

3D Continuous Casting Machine (CCM) and Pulpit Control Twin (Dual-arm rotary turret, tundish, 4 casting strands and synchronous torch-cut cars)

STEP 05

Turnover Cooling Bed, Robotic Barcoding and Semi-Finished Billet Yard

Tracks hot billets across the turnover cooling bed, assigns unique identity via robotic end-stamping and barcode tagging, and routes billets either to the billet stockyard or directly to the rolling mill reheating furnace for hot charging.

1. Operator Screens (POD)

Billet Length/Piece Counting and Production Confirmation Screen
Billet Marking and Barcode Verification Screen
Confirmation Reversal and Semi-Finished Stock Return Screen

2. Shift Supervisor & Control

Billet Yard Layout and Inventory Monitor
ERP – Automation Integration Queue Monitor

3. Quality & Laboratory

Billet Quality Approval and Characteristic Comparison Screen

4. 3D Digital Twin & Warehouse

3D Cooling Bed, Robotic Barcoding and Billet Yard Twin (Walking-beam thermal gradient visualization and 3D heat-to-billet genealogy)

SECTOR 02Heavy Industry & Hot Forming

Iron & Steel · Hot Rolling Mill, Reheating Furnace and Wire Rod / Bar Mill

In hot rolling mills, semi-finished billets are fed by overhead bridge cranes to the furnace charging table, heated above 1200°C across reheating furnace zones, rolled through roughing, intermediate and finishing stands into target bar, profile or wire rod sections, cooled on the cooling bed, cut to length, inspected and bundled. The field architecture governs every screen from billet charging to 3D warehouse bay storage.

Sector Detail Page →

STEP 01

Billet Selection, Overhead Crane Feeding and Furnace Entry Verification

Manages selection of billets from the stockyard or continuous caster according to the active rolling order, overhead crane loading onto the charging table, and camera/scale verification of length, weight and heat number prior to furnace charging.

1. Operator Screens (POD)

Billet Allocation List and Crane Feeding Operator Screen
Furnace Entry Camera / Barcode Verification and Charging Screen
Raw Material Return and Unmatched Billet Management Screen

2. Shift Supervisor & Control

Rolling Mill Order Management and Active Campaign Selection Screen
Component Allocation and Billet Consumption Reconciliation Report

3. Quality & Laboratory

Incoming Billet Quality, Heat Analysis and Spectrometer Verification Screen

4. 3D Digital Twin & Warehouse

3D Billet Stockyard and Furnace Entry Twin (Overhead bridge crane, billet stacks, entry camera checkpoint and live charging flow)

STEP 02

Reheating Furnace Walking-Beam Tracking, 3-Zone Thermal Process and Billet Map

Tracks step-by-step billet progression through preheating, heating and soaking zones via walking-beam strokes, visualizing each slot by order and heat color while verifying discharge temperature and descaling pressure.

1. Operator Screens (POD)

Reheating Furnace Order and Process Operator Screen
In-Furnace Billet Slot Position, Heat Color and Dwell Time Map
Furnace Discharge Temperature and Descaler Pressure Monitor

2. Shift Supervisor & Control

Reheating Furnace Dashboard and Furnace Readiness Report
Natural Gas Shift and Dimension-Specific Energy Consumption Report

3. Quality & Laboratory

Furnace Zone Temperatures, Soaking Time and Thermal Quality Monitor

4. 3D Digital Twin & Warehouse

3D Reheating Furnace SCADA and Digital Twin (FIFO billet array, color-coded heat transitions, 3-zone thermal map and SCADA-MES piece reconciliation)

STEP 03

Hot Rolling Mill Line, Main Pulpit Tower and Specific Energy Monitoring

Controls rolling of discharged billets through roughing, intermediate and finishing stands into target diameter/section, tracking line speed, micro-stops, roll groove/pass life (PRT), cobbles and water/electricity consumption from the Main Tower.

1. Operator Screens (POD)

Hot Rolling Line and Main Tower Operator Screen
Micro-Stop and Breakdown / Downtime Reason Entry Screen
Roll Pass / Groove Calibration (PRT) and Shift Crew Screen

2. Shift Supervisor & Control

Control Tower Live Production Monitoring Display
Rolling Mill OEE, Lost Time and Downtime Analysis Report
Hourly Output, Water and Electrical Energy Monitoring Panels

3. Quality & Laboratory

Rolling Dimensional Gauge and Hot Sample Tracking Screen
Production Scrap and Mill Cobble Report

4. 3D Digital Twin & Warehouse

3D Hot Rolling Mill Line Twin (Furnace discharge, roughing/intermediate/finishing stands, in-mill bar flow, stop alerts and live OEE cards)

STEP 04

Cooling Bed, Cold Shear, Abrasive Saw Cutting and Surface/Crack NDT

Coordinates bar cooling across the walking-beam cooling bed, cutting to customer lengths on cold shear or abrasive saw lines, mechanical tensile testing, and surface/subsurface crack verification at the automated NDT station.

1. Operator Screens (POD)

Cooling Bed Monitoring Screen
Cold Shear and Abrasive Saw Cutting Operator Screen
Surface and Crack Inspection (NDT) Operator Screen

2. Shift Supervisor & Control

Cooling Bed and Saw Cutting Performance Reports
Digital Shift Book and Shift Handover Panel

3. Quality & Laboratory

Non-Destructive Crack Testing (NDT) Defect Report
Mechanical Tensile/Yield Test and Lab Sample Entry Screen

4. 3D Digital Twin & Warehouse

3D Finishing and Quality Line Twin (Live simulation of cooling bed, cold shear, saws, NDT inspection station and sorting tables)

STEP 05

Bundling, Strapping, End Painting, Labeling and 3D Finished Goods Warehouse

Completes automated stacking and strapping of bars or coils, bundle weighing, steel-grade end-painting color indication, barcode tag printing and putaway into 3D finished warehouse bays.

1. Operator Screens (POD)

Bundling and Strapping Operator Screen
Production Confirmation, Heat-Based Confirmation and End-Paint Color Screen
Rejected Confirmation / Reversal Screen

2. Shift Supervisor & Control

Bundle Tracking and Finished Goods Production Panel
Warehouse-Level Production Confirmation and Dispatch Readiness Report

3. Quality & Laboratory

Finished Bundle Quality Release and Mill Test Certificate (EN 10204) Screen

4. 3D Digital Twin & Warehouse

3D Finished Goods Warehouse and Dispatch Digital Twin (Multi-row/tier 3D bay matrix, occupancy rates, bundle/heat lookup and dispatch simulation)

SECTOR 03High-Speed Process & Packaging

Fast-Moving Consumer Goods (FMCG) · Hygiene, Personal Care and High-Speed Packaging

In high-velocity consumer goods plants (baby care, wet wipes, personal care, cosmetics and home care), manufacturing runs across two linked tiers: semi-finished liquid/solution batching in mixer vessels and high-speed primary/secondary packaging lines producing hundreds of packs per minute. The shop-floor architecture governs mixer recipes, line-side FIFO component validation, PLC-driven OEE/Andon boards, end-of-line palletizing and 3D warehouse putaway.

Sector Detail Page →

STEP 01

Chemical / Semi-Finished Solution Batching and Mixer (Drop) Process

Controls recipe-based raw material weighing with loadcell tolerance checks in preparation vessels (mixers) for wet wipes, baby care and liquid personal care products, confirming each batch ('Drop') into the packaging line feed queue.

1. Operator Screens (POD)

Semi-Finished Order and Solution Mixing Operator Screen
Mixer Drop (Vessel/Batch) Consumption and Output Confirmation Screen
Active Solution Queue and Semi-Finished Quantity Adjustment Screen

2. Shift Supervisor & Control

Mixer – Plant and Work Center Assignment Panel
Chemical Monthly Capacity and Semi-Finished Final Output Report

3. Quality & Laboratory

Semi-Finished Laboratory Sample Result Viewer
Loadcell and Chemical Tolerance Master Data Management Screen

4. 3D Digital Twin & Warehouse

3D Plant Digital Twin — Semi-Finished & Mixer Zone (Preparation tanks, active solution orders and line feed status)

STEP 02

Line Setup, Roll / Packaging FIFO Feeding and Sanitation

Manages FIFO-sequenced loading of nonwoven fabric, film/foil reels and packaging materials via handheld terminals and cradle scanners, alongside pre-start sanitation, cleaning and calibration checks.

1. Operator Screens (POD)

Production Setup and Active Order Selection Screen
Reel Loading and Handheld Terminal Barcode Verification Screen
Final Product Component / Raw Material Consumption Screen

2. Shift Supervisor & Control

Order Sequencing and Shift Order Planning Screen
FIFO Quantity Update and Shift Crew Assignment Panel

3. Quality & Laboratory

Sanitation and Line Cleaning Verification Report
Machine Calibration and Characteristic Check Screen

4. 3D Digital Twin & Warehouse

3D Primary Loading and FIFO Material Twin (3D visualization of line-side FIFO batches with batch-aging color indicators)

STEP 03

High-Speed Production, Filling, Centralized Inkjet Coding and OEE Andon

Coordinates wetting/slitting/folding on primary lines or liquid filling into bottles/canisters, drives Inkjet printers automatically from MES with batch/date formats, and streams live PLC speed, downtime and OEE metrics.

1. Operator Screens (POD)

Final Product Operator POD (Wet Wipes, Baby Care, Liquid/Cologne, Canister Filling)
Centralized Inkjet Format Selection and Print Verification Screen
Downtime Entry, Downtime Splitting and Breakdown Notification Screen

2. Shift Supervisor & Control

Line-Level and Plant-Wide Live OEE Andon Boards
Hourly, Daily and Monthly Output / PLC Counter Reports
Mean Time Between Failures (MTBF) and Detailed Downtime Pareto Reports

3. Quality & Laboratory

Periodic Digital Quality Inspection Form and Result Screen
Quality-Production Monitoring and In-Process Line Check Report
Inkjet and Cradle Scanner Read Verification Report

4. 3D Digital Twin & Warehouse

3D High-Speed Line Digital Twin (Primary/secondary flow animation across 12 lines, running/stopped filtering and live PLC counter/OEE cards)

STEP 04

Secondary Packaging, Case Packing, Palletizing and Order Completion

Manages case packing of individual packs, palletizing, pallet label printing, single or bulk pallet production confirmations, and order closure with remaining semi-finished/packaging balance reconciliation.

1. Operator Screens (POD)

Final Production Confirmation and Order Completion Screen
Single and Bulk Pallet Management and Label Printing Screen
Production Confirmation Reversal Operator Screen

2. Shift Supervisor & Control

Digital Shift Book and Supervisor Logbook Screen
Confirmation Reversal Approval and Governance Panel
Activity, Material Consumption and Scrap Reports

3. Quality & Laboratory

Final Product Sample Result and Quality Release Screen

4. 3D Digital Twin & Warehouse

3D Secondary Packaging and Produced Pallets Twin (End-of-line palletizing simulation and live monitoring of released vs. pending pallet queues)

STEP 05

Floor Buffer Stock, Elevator/Conveyor Transfer and 3D Finished Warehouse Putaway

Tracks end-of-line pallets from floor buffer stock through goods receipt, elevator and conveyor transfer into the target finished goods warehouse, with warehouse clerk confirmation and 3D bin aging/occupancy monitoring.

1. Operator Screens (POD)

Finished Warehouse Clerk Pallet Receipt and Transfer Screen

2. Shift Supervisor & Control

Production-to-Warehouse Pallet Flow and Buffer Stock Aging Panel

3. Quality & Laboratory

Pre-Putaway Batch, Quarantine and Blocked Stock Verification

4. 3D Digital Twin & Warehouse

3D Pending Pallets and 3D Warehouse Digital Twin (5-stage pallet flow: Primary → Secondary → Goods Receipt → Elevator → Target Warehouse, plus 3D rack/bin occupancy map)

SECTOR 04Continuous Process, LGV & Converting

Paper & Converting · Tissue Paper, Parent Jumbo Roll and Converting Lines

In integrated tissue paper and converting plants, manufacturing begins with recipe-controlled blending of long-fiber, short-fiber and broke pulp bales, followed by winding giant 'Tambour' (Parent/Jumbo) rolls on the paper machine and slitting them on the rewinder. Slit parent reels are transported autonomously by Laser Guided Vehicles (LGVs) to intermediate storage or directly to converting lines (toilet tissue, kitchen towel, napkin, facial tissue), embossed, perforated, packaged and palletized. The field architecture unifies this entire flow.

Sector Detail Page →

STEP 01

Pulp Raw Material Preparation, Furnish Blend Recipe and Chemical Dosing

Manages selection of long-fiber, short-fiber and broke bales from inventory, charging into the pulper line according to the pulp blend recipe, and automated wet-end chemical dosing.

1. Operator Screens (POD)

Pulp Combination (Furnish Blending) Operator Screen
Long Fiber, Short Fiber and Broke Charge Addition Screens
Paper Machine Chemical Automation and Dosing Monitor

2. Shift Supervisor & Control

Pulp Blend and Recipe Compliance Report
Order Release and Order Priority/Sequence Management Screen

3. Quality & Laboratory

Pulp and Incoming Raw Material Quality Inspection Screen

4. 3D Digital Twin & Warehouse

Plant Inventory and Order Components View (Live pulp and semi-finished stock by storage location, batch and work center)

STEP 02

Paper Machine — Tambour (Parent/Jumbo Roll) Winding and Rewinder Slitting

Controls winding of tissue web into giant 'Tambour' (Parent/Jumbo) rolls at the paper machine reel-up, slitting into customer or converting widths at the rewinder, weighing and individual barcode labeling.

1. Operator Screens (POD)

Paper Machine Operator Panel (POD) and Order Detail Screen
Tambour (Jumbo Roll) Creation and Tambour List Screen
Slit Parent Reel List and Label Printing Screen

2. Shift Supervisor & Control

Paper Machine OEE, Daily and Monthly Production Efficiency Report
Paper Machine Trim Loss / Broke and Yield Report
Order Analysis and Order Closure Management Screen

3. Quality & Laboratory

Paper Machine Quality Result Entry and Usage Decision (UD) Screen
Statistical Quality Control (SQC), Paper Anomaly and Non-Standard Reel Screen

4. 3D Digital Twin & Warehouse

Live Speed and Trend Monitor (Paper machine instantaneous m/min speed, shift average speed and output trend charts)

STEP 03

Reel Grouping and LGV (Laser Guided Vehicle) Autonomous Logistics

Pairs slit parent reels at the paper machine left/right exit stations and dispatches Laser Guided Vehicles (LGVs) for autonomous transport to semi-finished storage or directly to converting line unwind stands.

1. Operator Screens (POD)

Paper Machine Reel Grouping Screen
Converting Reel Grouping and LGV Reel Call-Off Screen
Semi-Finished Reel Inventory Creation Screen

2. Shift Supervisor & Control

Stock Reclassification and Attribute Change Panel
Reel Inventory Movement and Traceability Log Screen

3. Quality & Laboratory

Pre-Transfer Non-Standard / Blocked Reel Interlock Check

4. 3D Digital Twin & Warehouse

LGV Autonomous Transfer and Reel Pairing Panel (Live mission and status monitoring of left/right reel stations and LGV fleet)

STEP 04

Converting Lines (Perforation, Embossing, Winding, Log Saw and Packaging)

Tracks parent reel unwinding and consumption on converting lines, monitoring line speeds, speed losses, product group changeovers, Henkaten (change point) logs, downtimes and automated maintenance (PM) requests.

1. Operator Screens (POD)

Converting Operator Panel (POD) and Parent Reel Consumption Screen
Downtime Entry, Automated Downtime Splitting and Maintenance Request Screen
Shift Operator Checklist and Henkaten Change-Point Screen

2. Shift Supervisor & Control

Converting OEE, Tonnage and Shift Production Reports
Top Downtimes, MTBF, Maintenance Stops and Group Changeover Reports
Work Plan and Machine Hierarchy Management Screen

3. Quality & Laboratory

Converting Quality Result and Usage Decision (UD) Screen
Converting SQC and Non-Standard Product Management Screen

4. 3D Digital Twin & Warehouse

Plant Monitoring Cockpit (Live plant board displaying running state, speed, active order and downtime status across all paper machines and converting lines)

STEP 05

Palletizing, Forklift Operations and Finished Goods Warehouse Management

Completes palletizing of cases from converting lines, individual pallet label printing, digital forklift shift checklists and warehouse transfer with inventory reconciliation.

1. Operator Screens (POD)

Pallet Production Confirmation and Label Printing Screen
Forklift Operator Pre-Shift Checklist Screen
Production Confirmation Reversal Screen

2. Shift Supervisor & Control

Pallet Administration Panel
Forklift Inspection and Energy Consumption Report
Integration Queue Monitor and System Parameters Panel

3. Quality & Laboratory

Final Pallet Quality Release and Full Track-Record Genealogy Report

4. 3D Digital Twin & Warehouse

Warehouse and Inventory Control View (Real-time matching of finished/semi-finished warehouse locations, batch stock and active work center requirements)

SECTOR 05Assembly Lines & Serial Production

Discrete Manufacturing · Home Appliances, Electromechanical and Automotive Tier-1

In home appliance, electromechanical and automotive supplier plants, production starts in press shops and body preparation cells, advances along multi-station serial assembly lines and concludes at electrical safety and functional test booths. By assigning a unique serial number (SFC) to every unit, the shop-floor architecture governs station transitions, critical component marriages, torque values and test results in real time.

Sector Detail Page →

STEP 01

Press Shop, Metal Stamping and Sub-Assembly Cell Production

Manages stamping of sheet metal coils on press lines, die stroke/life monitoring and kanban/batch transfer of stamped body sub-assemblies to paint lines or pre-assembly supermarkets.

1. Operator Screens (POD)

Press Line Operator Panel (POD) and Batch Confirmation Screen
Die Changeover (SMED) and Die Stroke Counter Monitor
Downtime and Breakdown Notification Screen

2. Shift Supervisor & Control

Press Shop OEE and Die Performance Report
Semi-Finished Supermarket Stock Level Monitor

3. Quality & Laboratory

First Piece Approval (FPA) and Dimensional Gauge Screen

4. 3D Digital Twin & Warehouse

3D Press Shop and Semi-Finished Supermarket View (Press line operating status and line-side buffer occupancy map)

STEP 02

Body Preparation, Surface Treatment and Paint / Enamel Line Tracking

Tracks welded or stamped bodies through surface cleaning, paint booths or enamel furnaces, monitoring overhead hanger carriers, bath/oven parameters and visual inspection results.

1. Operator Screens (POD)

Paint / Surface Treatment Hanger Loading and Unloading Screen
Visual Defect Coding and Touch-Up / Rework Routing Screen

2. Shift Supervisor & Control

Surface Treatment Line Speed and First Pass Yield (FPY) Panel

3. Quality & Laboratory

Coating Thickness, Colorimetry and Bath Parameter Quality Screen

4. 3D Digital Twin & Warehouse

Overhead Conveyor and Furnace Process Telemetry Panel

STEP 03

Multi-Station Assembly Lines, Barcode Component Validation and Poka-Yoke

Assigns a unique serial number (SFC) to each unit moving across assembly stations, displaying visual work instructions on the POD, validating critical component barcodes against the BOM and logging smart torque results.

1. Operator Screens (POD)

Assembly Station Operator Panel (POD) and Visual Work Instruction Screen
Barcode Component Marriage (As-Built Genealogy) Screen
Line-Side Material Call-Off (Andon / Replenishment) Screen

2. Shift Supervisor & Control

Assembly Line Balancing, Takt Time and Station Bottleneck Monitor
Line-Wide Live Andon and Target vs. Actual Output Board

3. Quality & Laboratory

Poka-Yoke (Interlock) Violation and Torque Tightening Result Monitor

4. 3D Digital Twin & Warehouse

3D Assembly Line Digital Twin (Station takt time, bottleneck/stop alerts and line-side material buffer status)

STEP 04

Electrical Safety, Performance Test Booths and Closed-Loop Rework Routing

Executes automated electrical safety, leak and functional testing of assembled units, automatically routing failed units to rework stations and blocking final packing until re-test pass.

1. Operator Screens (POD)

Test Booth Live Result and Automated Disposition Screen
Rework Station Fault Diagnosis and Corrective Action Screen

2. Shift Supervisor & Control

First Pass Yield (FPY) and Defect Pareto Report

3. Quality & Laboratory

Test Rig Parameter/Limit Governance and Quality Hold Screen

4. 3D Digital Twin & Warehouse

Test Booths and Closed-Loop Rework Flow Monitor

STEP 05

As-Built Unit Genealogy, Rating Plate Printing, Packing and Dispatch

Prints the final rating plate only after all assembly and test steps pass, marries the unit to carton and pallet barcodes, and archives the complete As-Built Genealogy upon finished warehouse handover.

1. Operator Screens (POD)

End-of-Line Final Pass Verification and Rating Plate Print Screen
Unit – Pallet Marriage and Packing Confirmation Screen

2. Shift Supervisor & Control

Shift Production Completion and Dispatch Readiness Report

3. Quality & Laboratory

Unit Serial Number (SFC) As-Built Genealogy Query Screen

4. 3D Digital Twin & Warehouse

3D Finished Goods Warehouse and Dispatch Stagings View

SECTOR 06Electronics & High-Granularity Traceability

Electronics, Surface-Mount (SMD) PCBA and Precision Device Manufacturing

In electronic board (PCBA) and precision device manufacturing, thousands of micro-components must be loaded from the right component reel onto the right pick-and-place feeder slot, moisture-sensitive devices (MSDs) must be monitored for open floor life, and every board must pass AOI, X-Ray and functional tests before final device marriage. The shop-floor architecture delivers complete component-reel-to-device traceability.

Sector Detail Page →

STEP 01

SMD Component Preparation, Reel-to-Feeder Verification and MSD Floor-Life Tracking

Manages unique barcode labeling of electronic component reels, BOM and approved-alternate verification during feeder slot loading, and open floor-life countdown tracking for Moisture Sensitive Devices (MSDs).

1. Operator Screens (POD)

Component Reel Setup and Feeder Slot Verification Screen
Moisture Sensitive Device (MSD) Open Floor-Life Monitor

2. Shift Supervisor & Control

SMD Line Setup Verification and Missing Component Alert Panel

3. Quality & Laboratory

Incoming Component Quality and Alternate Part Approval Screen

4. 3D Digital Twin & Warehouse

SMD Supermarket and Smart Reel Rack Inventory View

STEP 02

Laser PCB Marking, Solder Paste Printing, SMD Placement and Reflow Oven

Controls laser etching of unique 2D DataMatrix codes onto multi-board PCB panels, solder paste & stencil life checks, high-speed SMD pick-and-place execution and board-level reflow thermal profile logging.

1. Operator Screens (POD)

SMD Line Operator Panel (POD) and Panel/Board Tracking Screen
Solder Paste Exposure and Stencil Life Tracking Screen

2. Shift Supervisor & Control

SMD Line OEE, Placement Speed and Component Pickup-Error Report

3. Quality & Laboratory

Reflow Oven Thermal Profile and Solder Joint Quality Monitor

4. 3D Digital Twin & Warehouse

3D SMD Placement Line and Reflow Oven Telemetry View

STEP 03

Automated Optical Inspection (AOI / X-Ray) and Visual Defect Classification

Scans reflowed boards in AOI and X-Ray machines, displays flagged defect coordinates on the operator review terminal, and separates true defects from false calls before routing to touch-up/rework.

1. Operator Screens (POD)

AOI / X-Ray Defect Verification and Pin/Component Diagnostic Screen
PCBA Touch-Up and Rework Station Screen

2. Shift Supervisor & Control

Board and Component Defect Density (PPM) Report

3. Quality & Laboratory

Soldering Defect Analysis Screen (Bridging, Missing Component, Tombstoning)

4. 3D Digital Twin & Warehouse

Visual PCB Defect Map Overlay Screen

STEP 04

In-Circuit Test (ICT), Firmware Flashing and Functional Calibration

Automatically flashes the order-specific firmware version onto depanelized PCBA boards, executes ICT and Functional Test (FCT) sequences, and records calibration parameters into the board genealogy.

1. Operator Screens (POD)

Automated Firmware Flashing and Version Verification Screen
ICT and Functional Test (FCT) Operator Screen

2. Shift Supervisor & Control

Test Station Cycle Time and First Pass Yield (FPY) Panel

3. Quality & Laboratory

Electronic Test Logs and Calibration Certificate Screen

4. 3D Digital Twin & Warehouse

Test Stations Live Status and Queue Monitor

STEP 05

Final Box-Build Device Assembly, Electronic As-Built Genealogy and Packing

Combines tested PCBA sub-assemblies into the final device enclosure, links sub-board serial numbers to the parent device serial number, prints hierarchical box/pallet labels and archives the complete electronic genealogy.

1. Operator Screens (POD)

Final Box-Build Assembly and Sub-Board Marriage Screen
Device – Carton – Pallet Hierarchical Packing Screen

2. Shift Supervisor & Control

Order Completion and Dispatch Traceability Report

3. Quality & Laboratory

Bidirectional Component-Reel-to-Device Genealogy Query Screen

4. 3D Digital Twin & Warehouse

3D Finished Goods Warehouse and Dispatch Staging View

PLANT DISCOVERY & ARCHITECTURAL ASSESSMENT

Let Us Architect the Optimal Screen and Process Workflow for Your Plant.

In a technical architectural assessment session, we review your existing ERP, PLC/Level-2 automation and shop-floor operations to establish a phased implementation roadmap.

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