Y O U R M A N U F A C T U R I N G E X E C U T I O N S Y S T E M
Roll Manufacturing & Converting Excel lence
GRASSM A N U F A C T U R I N G . E X C E L L E N C E .
Page 2
ABOUT US
Being the industry specialist we exactly know and understand your specific
requirements. We speak your langua-ge and you don’t need to train our
consultants before they understand your processes and add the value you
expect. Success arises from experience and
best practices, paired with individuali-ty and the spirit of innovation.
For now more than 30 years Grass GmbH is a proven industry spe-
cialist and a leading supplier for manufacturing-related standard
software and consulting services within the roll manufacturing and
converting industry. We offer the perfect MES-solution for your roll-
specific manufacturing and converting processes. Furthermore we
offer respective consulting services to identify additional productivi-
ty potentials within your company. In addition our success is based
on a culture of partnership and collaboration with our customers
and suppliers and on our specific and customer-centric solution.
Our powerful and proven Manufacturing Execution System COAGO
increases transparency and efficiency of your manufacturing and
converting processes around films, papers, textiles, nonwovens or
rolls, webs, formats and sheets.
Highly reputable clients rely on our software solution and consulting
expertise in regard to their manufacturing success.
Page 3
Already 5.000 users located on nearly 25 sites in Germany, Austria,
Switzerland, Spain, Portugal, Thailand, China, Russia, Canada and the
USA are supported by our Manufacturing Execution System COAGO.
We are proud to include leading manufacturers of food and pharmaceu-
tical films, high-tech barrier films, laminating films, label films, decor,
furniture and window films, technical films, cup and blister lidding and
packaging films in our client repertoire.
Surely many of them are very familiar to you, most of them either as
clients, suppliers and/or competitors.
SUCCESSFUL WORLDWIDE
Consulted Manufactures Germany, Austria, Switzerland, Spain, Portugal, Thailand, China, Russia, Canada, USA
References Bilcare Research Constantia Patz Kalle Klöckner Pentaplast Mondi Renolit SE
Clear Industry Focus
Company/Product Strategy
Future Viability and Security of Investment
Stability and Independence
Industry Expertise
Page 4
Investing in a new MES-solution is a key component of a production-
related IT-strategy. These investments usually reach significant dimen-
sions which shouldn‘t be questioned after two or three years but have
a sustainable strategic focus.
To secure important investments for the future you need partners,
technologies and product strategies that are proven and tested in the
industry. Once you have reached strategic potentials for future deve-
lopment of your enterprise your goal to invest in a sustainable solution
is achieved.
As an independent partner, we have successfully and fully dedicated
ourselves to serve the roll manufacturing industry. Our entire company
and product strategy is targeted exclusively to your industry to meet
your requirements - the best preconditions for sustainable success of
your MES-investments.
SAFE AND SUSTAINABLE INVESTMENT
Page 5
COAGO – the MES for your industry „made by specialists“.
Production is one of the most important links in the entire value chain.
The foundation for economic success is built on factors like quality, on-
time-delivery and cost-optimized performance.
A system which focusses on sustainably supporting and enhancing pro-
cesses of your value chain needs to be adjusted exactly according to the
production-related, industry-specific requirements of your enterprise.
It has to be able to cope with your specific production requirements
and perfectly enhance and support your manufacturing processes as
well.
COAGO is the industry solution targeted to all details and varieties
of the roll manufacturing and converting industry. You can
be sure that your specific requirements will be met
through COAGO-solutions, exclusively designed
for your industry and your specifications. True to
the motto: “made by specialists”.
MORE ADDED VALUE WITH COAGO
Everything E
veryw
here
Anyt m
e P
lanning
Contro
l M
onitor
Tran
sparency
Ef c
iency Excellence
Page 6
Top Management
Production Management
Controlling
Planning
Top Management is able to transparently access all decision relevant
production data at any time and make decisions based on reliable data,
facts and figures.
Production Management is able to permanently supervise the recent
situation of production online and has the chance to intervene before
errors may multiply. Key figures reveal possibilities for optimization
and measures can be evaluated according to the effect they render.
Controlling receives via safe and powerful interfaces reliable and con-
sistent feedback of cost relevant parameters.
The Planning Department is able to create an optimized sequence of
orders, monitor the production progress online and schedules can be
adjusted according to the actual situation on the shop floor.
BENEFITS FOR EVERYONE WITHIN YOUR COMPANY
Everything E
veryw
here
Anyt m
e P
lanning
Contro
l M
onitor
Tran
sparency
Ef c
iency Excellence
Page 7
Quality Management
Logistics
Customer Service
Worker
The Quality Management Department is able to model the inspection
planning and handle data aquisition using an integrated system. This
seamless integration of your production processes leads to higher speed
and increases transparency.
Logistics gain speed. The WIP stock is reduced, work stations are supplied
with the right materials and finished goods are removed according to
schedule.
Customer Service is able to inform customers about the status of the order
at any time. On-time-delivery and customer satisfaction increase.
The operator is able to focus on his machine and his product. He receives
all relevant information in a clear format and the system supports him
when processing the order.
EFFICIENCY AND EXCELLENCE THROUGH TRANSPARENCY
Goods Receipt Mixing Mother Rolls Converting Processing Packaging
Page 8
▪ Goods receipt such as rolls, formats, raw materials and buy-ins
▪ Mixing e.g. of granulates, colors, pastes or fibers
▪ Mother roll manufacturing e.g. at the calander, extruder or in the co-extrusion, at paper mills or on nonwoven lines.
▪ Converting such as coating, laminating, printing, embossing or stretching
▪ Processing e.g. roll or format slitters, punching, bags converting
▪ Packaging e.g. palettizing, labeling and shipping
▪ Re-Work e.g. re-winding, splicing
▪ Recycling e.g. grinding and re-compounding
Parallel to the Manufacturing Process
Detailed production planning, quality management, machine and
process data collection, specification management, reporting and con-
trolling
“A complete solution from goods receipt to palettes ready-to-ship.”
ALL PROCESSES IN ONE MES
Workflow Management
Controlling & Reporting
Order Combination
Scheduling & Planning
Roll Management
Maintenance Management
Service & Admin
Printouts & Labels
Logistics & Warehouse
Shop Floor Data
Process Data
Machine Data
Order & Phase Monitoring
Stock Replication
& ATP
SPECS
CAQ
Edge Trim
Interfaces
Schift Plan
Documents
Traceability
SPC
Page 9
COAGO offers sophisticated modules for the entire value chain of the roll manufacturing and roll converting industry.
Regarding this complete scope of features of a state of the art MES-solution, COAGO provides a complete range of modules. It´s typically linked between common ERP-systems and the machine control or PLC.
A HOMOGENE SOLUTION FOR YOUR PRODUCTION
FINE PLANNING. DATA HANDLING.
▪ Detailed Planning - Planning board with graphic visualization - Dispatching and replanning of orders - Combining or splitting of orders and operations - Plausibility checks and monitoring in case of replanning - Order-list visualization
▪ Electronic Order Papers - Order information - Specifications e.g. quantity, time, performance - Integrated documents
▪ Operational Data Collection - Reporting of order, machine and staff times - Quantities report e.g. locks, scrap, good materials - Catalog granularity in times and quantities - Text captioning for rolls/manufactured objects, QC and order - Continuous backflush to the ERP-system
▪ Roll Management - Dimensional modifications - Plausibility checks of length, width and weight - Qualified reports of rolls or formats such as lockings,
scrap, by-products - Integration and recording of inspection results - Text capturing of manufacturing objects and orders
Improvement through planning and actual data entry.
Page 10
Page 11
CAQ. TRACKING. REPORTING.
▪ Quality Management - Inspection planning - Inspection results aquisition - Inspection device integration - Analyses, evaluations, reportings - Certificates and accompanying documents
▪ Batch-Tracking - Multi-directional tracking - Change of tracking direction through drag & drop, e.g.
from the raw material to all customers and back - Flexible tracking start at any point of the production process,
e. g order, raw materials, manufacturing processes, rolls, formats, palettes, customers
- Export and print results - Drill-down into further modules, such as roll management,
CAQ
▪ Reporting & Controlling - Standardized reporting system, such as OEE, quantities, times,
quality, machine or process data - Variable parameter control management of reports - Chart or table visualization - Export as graphic or raw data - Machine overview, operation views
Identify opportunities. Realize potentials.
MDA & PDA. SPECS. LOGISTICS.
▪ Machine & Process Data - Integration of the PLC - Integration of mixing area and mixing devices - Integration of inspection devices such as camera based
web monitoring, „OCS“, black spot detection, thickness measurement
- Roll visualization and markings
▪ Specification Management - Machine datasheet and operation values - Check lists and plans e.g. cleaning plans, machine settings - Manual or automated result recording - Notification of exceptional situations or discrepancies - Reporting and trending
▪ Workflow Management - Design and direct context-related workflows - Make information transparent - Avoid mistakes - Process stability
▪ Logistics & Storage Management - Event-driven transportation orders - Integration of forklift systems and self-guiding transport systems - WIP-storage management - Material stock overview and inventory support - Picking and putaway strategies
Design, supervise and optimize processes.
Page 12
Page 13
ALLROUND SERVICE, EXCEPTIONAL SUPPORT.
▪ Support - 24/7 availability and on-call service for all time zones - Experienced support staff with customer know-how - Internet-based support and customer service center - Call monitoring and tracking - Individual service-level agreements
▪ Maintenance - 100% industry focus - Continuous improvement - Focused product development
▪ Value Added Services - Consulting in hardware-sizing and selection - Database management and administration - Virtualization - Network analysis and performance
enhancement - Realization of backup systems and emergency
concepts - Server installation and maintenance - Development of a complete COAGO environment
We are there for you whenever you need us.
Our service is as highly available as the production of our customers.
Page 14
NOTHING IS MORE CONVINCING THAN SUCCESS
Successful software projects in the manufacturing sector can only
be guaranteed by a partner who has gained extensive experience
within the value added processes of his customers and their up- and
downstream functions and systems. Furthermore our employees dis-
tinguish themselves by profound knowledge of methods and efficient
project management.
Our customers say it is pleasantly simple to work with us closely. They
appreciate our distinctive knowledge and the capability of collaborating
in a professional and innovative way.
»Stringent project management, a highly qualified team and many
years of industry knowledge. These are the key factors that Grass GmbH
used to successfully execute MES and Lean projects within a minimum
of time. We were highly satisfied. Thank you.«
Martin Klinkert, CIO, Renolit SEImage sources::© Tino Neitz, AA+W, Kaarsten, Victor Tongdee, krsmanovic, Guido Vrola, contrastwerkstatt, VRD, K.-U. Häßler, Minerva Studio, michaeljung TASPP, Laurentiu Iordache, Moreno Soppelsa, arahan, cultura2, fotoklatka, Kurhan, RGtimeline, jannoon028, industrieblick, Janina Dierks, FotolEdharFotolEdhar, Klaus Eppele - Fotolia.com. Maschine, Reifenhäuser GmbH & Co. KG Maschinenfabrik, Bilcare Research
Page 15
Rely on our long experience with rolls, formats and sheets. We offer
with COAGO we offer a MES-solution, which has set industry standards
and consulting services that reveal productivity potentials aimed
at increasing your performance.
Secure your company a place in the future.
Competitiveness begins in your production facilities - with lean proces-
ses, high utilization of your machines and equipment, avoiding waste
and employees focusing on the excellence of their products with a zero
error tolerance.
Moreover, with tools that show you at a glance where you are and in
what direction you are currently heading. You detect errors before they
happen and are able to intervene before they may disperse and affect
other processes.
ROUND ON OFFER
Goods receipt
VolumetricRecycling
MixerFlexography
Recipes
CalenderRegrinder
Co-Extruder
Sheetfed Printing
Coating
LaminatingWinder Rework
Gravure press
LogisticsLabelingPacking
ReportingPunching
Automation
Size sheeter
Extruder
Traceability
Web materials
SlitterBags converting
Embossing
Quality
Paper machine
Rolls Formats
Sheets
Pulper Gravimetric
COAGO MES Industry Software
Grass GmbH Kreuzstraße 24
55543 Bad Kreuznach Germany
Fon: +49.671.9289.0 Fax: +49.671.9289.111
E-Mail: [email protected]
© 2
013
Gras
s Gm
bH. A
ll Ri
ghts
Res
erve
d. C
OAG
O -
e - 0
3.20
13