Valeris®

Modern Manufacturing Execution System with seamless traceability, free configuration and intuitive operation

In order to remain competitive, manufacturing companies must continuously optimize their production processes - regardless of whether they are series, warehouse, individual or JIS manufacturers - no matter the industry. For some companies, complete process and product traceability is and will be mandatory. This no longer only concerns "sensitive" products and manufacturing processes. Last but not least, developments in the direction of Industry 4.0 and the Industrial Internet of Things (IIoT) enable processes to be optimized and new business models to be realized. And what development does your production take - does your MES keep up?

With VALERIS, we have developed a modern, web-based Manufacturing Execution System (MES) that takes all of the above aspects into account. It provides maximum transparency on the shop floor and supports process optimization to a high degree. VALERIS is freely configurable and extremely intuitive to use. All this relieves the IT department and saves valuable IT resources.

Seamless product and process traceability

VALERIS maps all production lines and work stations as digital twins and mirrors the processes on the shop floor and production logic one to one. VALERIS ensures a seamless traceability of manufactured products and processes.

Maximum process reliability and product quality

VALERIS enables a target/actual comparison of process parameters in real time as well as digital execution and confirmation of test instructions. In this way, faulty products can already be identified and discharged directly on the line. In addition, process interlocking functions automatically intervene if there are irregularities and, if necessary, block the further production of the product.

VALERIS MES Screenshot Tool

Intuitive operation thanks to UX (User Experience) design

VALERIS has an ultra-modern user interface in UX design. Dialog support intuitively, efficiently and reliably guides users through all process, configuration or administration steps. This also allows employees to quickly become familiar with the system.

Configuration instead of programming

Thanks to the low code modeling approach, logical relationships and dependencies of processes are mapped in VALERIS via a graphical editor for pre-defined actions (e.g. read/write/scan actions and more). Business users as well as process engineers can configure process and production parameters themselves easily and quickly without additional IT know-how. This frees up your in-house IT department and reduces the strain on your IT budget by eliminating the costs for external IT consultants.

MES VALERIS screenshot from program shows possibility of process modeling

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  • Industrie-4.0- and IIoT-ready

    VALERIS acts as a link between the field, control and company level. Using interfaces such as OPC-UA, Modbus, MQTT, Rest, EUROMAP 63 or 77, Industry 4.0 and IIoT scenarios can be implemented quickly and easily.

  • Individual dashboards and reports

    VALERIS makes it possible to create custom dashboards or reports quickly and easily. In this way, any employee/decision-maker can be provided with exactly the information they need to complete their tasks.

  • Work independently of hardware

    In order to achieve the highest possible system flexibility and scalability, VALERIS was deliberately designed as a web-based application. Work can be done via any hardware. A standard laptop, PC or industrial PC, for example, is perfectly adequate. All you need is a browser and Internet access. This saves costs in the long term (e.g. for purchase, maintenance, servicing, repairs).

  • Private Cloud, Public Cloud, Hybrid, On-Premise

    VALERIS can be used as a private cloud, public cloud, hybrid or also on-premise solution. The modern system architecture allows free scalability and flexibility. No matter which IT strategy is adopted today or tomorrow, VALERIS adapts.

  • ITIL-conform 24/7 Support from Germany

    We at WSW Software support you with our entire consulting and process know-how in the development and realization of your future MES concept and the implementation of VALERIS. We guarantee the smooth operation of VALERIS with ITIL-compliant support from Germany, around the clock (24/7) if required, and with flexibly scalable service level agreements. Since all services come from a single source, you will receive the best possible care and benefit from VALERIS.

Is VALERIS also suitable for my production?

VALERIS is an industry-independent MES for medium-sized series, warehouse, individual or JIS manufacturers and is aimed at companies that want to drive digitalization in their production and remain flexible at the same time.

  • We have high requirements for complete product traceability.
  • We produce in changing production processes.
  • We have limited IT resources and budgets.
  • We are looking for an expandable system that will grow with production.
  • We want a cost-effective solution that is quick to introduce.

 

Do any of the statements apply to your production? Then you should contact us!

Consultation

Would you like to sustainably optimize your Business Analytics processes in the SAP environment and manage your business in a flexible, transparent, and anticipating manner? We look forward to advising you. Please feel free to call or e-mail us.

VALERIS functional areas

According to the VDI guideline 5600, which describes the tasks of a production management system (MES), VALERIS covers the following functional areas:

  • Material (Traceability/WIP)
  • Equipment/Resources (PDC/Tool)
  • Order (BDE)
  • Informationen (performance/key figures)

Additionally we offer:

  • Master planning (control and planning functions for the master)
  • Worker qualification

VALERIS Modules

VALERIS machine coupling
Versatile connections via OPC-UA

The modules from the area of digitization enable automatic data acquisition by connecting the machines, assembly systems, measurement technology and sensors. The VALERIS machine coupling is based on OPC-UA and thus implements most of the desired connections such as S5/S7, E63/77, UMATI or Modbus.

Machine states, running times, status messages or weights, pressures and temperatures can be recorded, configured and documented via VALERIS. The data blocks also "talk" to each other if, for example, subsequent operations have to be interlocked with certain criteria or the worker has to confirm quality-relevant steps. The graphically supported configuration of the process logic saves effort and reduces errors in the process.

If necessary, you can change the machine connections independently.

MES VALERIS screenshot from program shows possibility of connecting various machines
VALERIS Process Designer
Have it done or do it yourself - your decision!

What does a modern ME solution actually have to offer? Our response: "Configuration instead of programming." Thanks to the low-code modeling approach, specialized users or process engineers can easily and quickly configure machine interfaces as well as process and production parameters themselves without additional IT know-how.

VALERIS has an ultra-modern user interface in UX-Design. Dialog support intuitively, efficiently and reliably guides users through all configuration steps.

Of course, we support you with our services such as training, consulting or even installation and configuration if required. Your choice!

MES VALERIS screenshot from program shows possibility to customize processes and machine interfaces
VALERIS Information
Answers the questions such as "What happened?", "What is the status?", "What are the current problems?", among others.

Are these questions part of your daily work? The module VALERIS Information helps you to answer these questions:

  • The data collected from the production process is clearly visualized in a dashboard and can be condensed into focus analyses.
  • You can compare current as well as historical data of plants, work steps and production areas, such as a critical machine, a particular article or certain key figures.

  • You can independently set your favorites, which you must have in view immediately.

MES VALERIS screenshot from program shows dashboard for manufacturing
VALERIS Material Management
Acquisition of process parameters in real time

VALERIS Material Management digitizes your production process to the highest degree and records the process parameters in real time. Plants, measuring devices, scanners, label printers or IT systems are connected bidirectionally. Your processes are automated. If necessary, defective components are automatically rejected.

Whether serial number, batch or assembly ... you record the components included in the manufacturing process online. The traceability of products and processes is guaranteed. And all at the push of a button!

MES VALERIS screenshot from program shows ability to manage materials
VALERIS Resources
Answers the questions "Where am I wasting production time?", "Why isn't availability at 100%?", "Can I use the resource?", among others.

If these are the questions you need answers to, then the VALERIS Resources module is the right choice. The module considers all resources that are required for production. You decide whether you want to keep an eye on machines, systems or assembly workstations, or whether you also want to monitor and optimize tools and equipment.

The module provides you with an overview of the availability, duration, condition and problems of the resources. This provides you with the basis for increasing the availability of the production resources used and getting more out of the capital invested.

VALERIS Order
Answers the questions "Why isn't the order ready yet?", "What does the next shift need to produce?", "Why aren't the cycles right?" among others.

VALERIS Order is your "sensor" in the production. This reduces the amount of confirmation required and automates the data flow between production and ERP - the basis for optimizing production and order throughput.

As classical PDC functions, orders/operations are registered at the worker dialogs, the production times are recorded and compared with the target or planned times. Here you can clearly see when deadlines are getting out of hand or which problems are occurring.

And if you have to react quickly, the VALERIS module Master Planning helps you to reschedule. By dragging and dropping, you assign workstations and use your expertise to decide what belongs together and should follow one another. VALERIS supports you with filter functions and temporary evaluations (e.g. set-up time totals) to make quick, well-founded decisions.

VALERIS Worker Qualification
Answers questions such as "Who can operate the equipment?", "Who do I need to train?", "Who has received what training?", "How do I pass my ISO audit?", among others.

The Worker Qualification shows you at the push of a button who has been trained on a system, when they last worked on it and when the knowledge needs to be renewed. A distinction can be made down to the product level.

With the supplementary module Worker Control, you can define what a worker can/should see in an input dialog (image, area, video, check mask, etc.) and what he can/should confirm. With the worker control, you prevent unqualified personnel from operating the system, which could result in incorrect work steps being carried out and/or errors being triggered.

The advantages? Both modules serve to reduce the number of committees and provide important proof of competence for ISO audits and product liability issues.

MES VALERIS screenshot from program shows which employees can operate certain machines
Logo des MES D.A.CH Verbands.

Important questions/answers on the topic of the Manufacturing Execution System (MES)

What does a Manufacturing Execution System do?

A Manufacturing Execution System (MES) directly supports the user in monitoring, controlling and documenting production processes. In addition, it acts as a link to make suitably prepared production data from the shop floor available to the Enterprise Resource Planning (ERP) systems in real time.

Which functions should every MES offer?

The core functions of an MES include components for machine data acquisition (MDE) and production data acquisition (PDA) as well as the possibility of being able to trace and document the manufacture of the product without gaps (material/traceability).

In addition, an MES offers the possibility of supporting quality-assuring processes in the development process. From the control of the workers via guided entry dialogs to the documentation of skills and instructions for or on specific machines/equipment/workplaces.

A suitable reporting module gives the user the possibility to visualize production figures - adapted to the user's needs - and thus to make the user's production transparent.

The basis, however, is the digital connection of workstations, consisting of machine coupling and worker dialogs. This is where the information from the production process flows into the MES. A very up-to-date view of plants, products or production areas is thus possible.

What are the advantages of using an MES?

The benefits of an MES are improved plant and machine productivity. This means that throughput times in production can be reduced.

In addition, the product quality increases, the adherence to delivery dates improves as well as the level of customer satisfaction.

Transparency is increased and changed conditions due to shutdowns/breakdowns are responded to more quickly.

MES is also a component of the documentation of the manufacturing process including the involved resources (human, machine, material, method) in the context of product liability.

What are the advantages of VALERIS as an ME system?

VALERIS is a modern, lean, robust software solution designed by usability experts with a focus on the user.

Whether a machine operator, production engineer or plant manager, every user is optimally supported by the front end. The digital mapping of processes, the creation of interactive dashboards and customer-oriented reports can be carried out independently by the user.

Of course, the core requirements of an MES according to VDI 5600, such as management of orders (BDE), equipment (MDE, tool), material (traceability, WIP storage) as well as machine coupling, are fulfilled. Process interlocking, complete traceability and transparency of the production process are also guaranteed.

We use a BDE system. Can I change to MES?

A generalization is not possible, but existing machine connections can almost always be reused. If the IT hardware used for the reporting terminals is approximately state of the art, it can often be reused.

At the application and database level, a change to modern systems should be made. Cloud systems (internal and external) are secure and reduce IT costs sustainably.

The transfer of data for the documentation of the processes can take place, but requires some effort. A case-by-case consideration is required, taking into account data protection concepts of the existing system.

What is the connection between MES and Industry 4.0?

The Smart Factory operating according to the principles of Industry 4.0, is the key. Here, all systems, processes, and data are interlinked consistently and control themselves.

The central component for this Smart Factory is the use of a modern MES that maps all production lines and workstations and communicates bi-directionally with the manufacturing systems via OPC UA and other interfaces.

This makes it possible to network data and processes horizontally on the shop floor and to make production completely transparent. This is an important prerequisite for further process optimization, seamless tracking and tracing and Industry 4.0 scenarios.

Another big step towards data migration is that the ME solution can be connected to an existing ERP system or a JIS and logistics platform via interfaces.