Manufacturing Execution Systems (MES) are essential tools in modern production environments, enabling organisations to optimise their operations from the ground up. Greycon’s MES solution, GreyconMill, is designed specifically to address the unique needs of roll-based, flexible packaging and converting industries, such as paper, plastic film, nonwovens and metals. GreyconMill enables optimal planning, execution, and control of production processes, all while ensuring complete traceability throughout the workflow.

Enhanced Production Efficiency

One of the standout features of GreyconMill is its ability to enhance production efficiency. By providing real-time monitoring and control of production processes, the system empowers operators and managers to make quick adjustments that can significantly improve productivity. Immediate insights allow for faster responses to issues, minimising downtime and reducing material waste. This real-time control ensures that production lines are optimised, leading to higher throughput and more efficient use of resources.

Improved Quality Control

Maintaining high-quality standards is essential in competitive manufacturing industries, and GreyconMill integrates quality control directly into the production process. By capturing and analysing quality data in real-time, it enables operators to identify and address quality issues before they become costly defects. This proactive approach reduces the risk of producing off-spec materials, enhances customer satisfaction, and minimises rework or scrap. Ultimately, GreyconMill ensures that production meets quality standards from start to finish.

Better Inventory Management

Effective inventory management is crucial for maintaining production continuity and minimising costs. GreyconMill provides precise tracking of raw materials, work-in-progress (WIP), and finished goods, offering complete visibility into inventory levels. By automating inventory updates and reducing manual tracking, helps prevent stockouts or overstocking situations, ensuring that the right materials are available when needed, and reduces the risk of losing items or allowing them to age due to lack of visibility. This precise inventory management supports lean manufacturing practices and lowers operational costs.

Streamlined Workflow

GreyconMill excels in automating various production processes, minimising the need for manual interventions. By reducing reliance on human inputs, the system not only accelerates workflows but also reduces the potential for errors. This automation leads to a smoother, more streamlined workflow, freeing up employees to focus on value-added tasks rather than manual data entry or troubleshooting. The result is a more efficient and reliable production process that delivers consistent results.

Reporting and Analytics

Data-driven decision-making is critical in today’s competitive manufacturing landscape. GreyconMill collects and analyses vast amounts of data from the production floor, generating detailed reports and insights on performance metrics. These reports enable managers to assess production efficiency, quality control, inventory levels, and asset utilization, helping them make informed decisions for continuous improvement. By monitoring key business performance metrics, such as Overall Equipment Effectiveness (OEE), GreyconMill highlights bottlenecks and idle times, providing actionable insights that can lead to improved production strategies, enhanced quality standards, cost savings, and greater operational efficiency.

Increased Transparency and Traceability

Transparency and traceability are key requirements in industries with strict compliance and quality assurance standards. GreyconMill offers full visibility into production processes, allowing manufacturers to track materials from raw input to finished products. This level of traceability is critical for meeting regulatory requirements, ensuring product quality, and maintaining customer trust. In the event of any issues, manufacturers can trace back problems to their source and take corrective actions quickly.

Seamless Integration for Your Roll Environment

GreyconMill is designed to integrate seamlessly with other enterprise systems, including Enterprise Resource Planning (ERP) systems and Greycon’s advanced planning, scheduling, and trim optimization tools. This integration ensures a cohesive flow of information across the enterprise, from production to inventory to scheduling. By synchronising data across different systems, GreyconMill eliminates data silos and enables better decision-making at every level of the organisation.

Raw Materials Consumption, Runtime and Downtime Costs

In manufacturing, raw materials consumption, runtime, and downtime costs are essential for both traceability and real-time production costing. GreyconMill’s functionality allows for detailed monitoring of raw material usage, linking this directly to product cost and inventory management. By capturing runtime data, GreyconMill enables visibility into operational costs tied to machine usage, facilitating better resource allocation and production planning. Downtime tracking, a core feature, highlights delays and inefficiencies that can impact productivity and elevate per-unit costs. Overall, GreyconMill’s real-time tracking empowers manufacturers to make informed decisions that optimize cost-effectiveness while ensuring traceability throughout production.

Goods Receipt and Dispatch

In GreyconMill, Goods Receipt and Dispatch processes are streamlined using state-of-the-art mobile applications that enhance accuracy and efficiency. These mobile tools allow operators to reduce picking time by providing real-time access to inventory and dispatch data, optimizing the flow of goods through the facility. Automated features help prevent errors, ensuring that the correct materials are picked and shipped, reducing costly mistakes. Additionally, paperwork is digitized and automated for transportation, which not only accelerates processing but also improves traceability and compliance with shipping requirements. By integrating mobile applications into Goods Receipt and Dispatch, GreyconMill enables a faster, more reliable, and paperless operation.

Conclusion

GreyconMill is a powerful MES solution tailored for roll-based industries, offering significant benefits in production efficiency, quality control, inventory management, and beyond. Its advanced features, combined with seamless integration capabilities, make it an essential tool for manufacturers seeking to improve their operations and maintain a competitive edge in today’s dynamic markets.