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Reasons and benefits for Cosmino Panteo

Use cases and experience from over 35 years as a digitization partner

Use cases, we encounter every day

For over 35 years, we have been helping companies digitize their production with PDA, MDA, and MES. In doing so, we have encountered many typical challenges—and many good reasons why customers have chosen Cosmino Panteo.

The following anonymized and condensed practical storys show typical cases from everyday manufacturing life that we have also experienced in a similar way. They illustrate why Cosmino Panteo was used in these situations – and what concrete benefits our customers were able to achieve with it.

Perhaps you recognize yourself in one or two of these situations and needs.

Set aside thousands of euros anual for machine damage – or digital prevention?

Production manager Mr. Müller finds a simple digital solution to a problem that costs thousands of euros every year.

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Invest as usual in more capacity or in a sustainably use of existing capicity?

High costs, limited capacity, and then the crucial question: Does a new machine really bring the greatest benefit – or is there a better lever?

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From Excel chaos to digital transparency – why the new plant manager calls us

As Mr. Schneider takes over as plant manager and asks for reports, he’s shown a one-man system – and that man is retiring. What follows is a move toward transparency, efficiency, and future readiness.

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Cosmino Panteo Functional Overview for PDA, MDA, and MES

Cosmino Panteo is both a software and a toolbox that we use to optimally implement your project requirements. Below you will find a list of core functions that are frequently used in projects.

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Typical benefits and effects of PDA, MDA, and MES systems

The advantages listed here are among the typical effects that companies achieve with digital manufacturing systems such as PDA, MDA, and MES.

With Cosmino Panteo, we have successfully realized this potential in numerous projects.

Transparency in production

  • 100% Transparency: An MES provides complete visibility into all production processes. This level of transparency helps identify and reduce organizational waste such as waiting times, material shortages, or idle time.
  • Better Decision-Making: Whether it’s operators, team leaders, or plant management, real-time data enables informed decisions at the right moment—based on facts, not gut feeling.
  • Problem Prevention: Real-time data immediately highlights deviations—before they become actual problems. This reduces unplanned downtime and increases process stability.
  • Reduced Waiting Times: Waiting times and similar organizational inefficiencies are minimized through instant notifications, need-based escalation, and transparent reporting. This significantly boosts individual motivation to reduce delays across all teams.
  • Lean Management: MES systems support the identification and elimination of waste—be it unnecessary movement, waiting times, or overproduction.
  • Targeted Investments: With clear insights into processes, investments can be made more strategically—where they generate the greatest benefit.
  • Cost Transparency: Fully captured actual data enables realistic cost estimation and transparent post-calculation for each order—resulting in better margins and more reliable decision-making.
  • Realistic Cost Assessment: Timely ERP feedback with actual production data ensures accurate, real-world cost analysis.
  • Optimized Maintenance: Scheduled maintenance and tool changes help prevent breakdowns.

Efficiency increase

  • OEE Improvement: Cosmino Panteo supports you in improving Overall Equipment Effectiveness (OEE). Especially when there was previously little to no structured data collection or analysis in place, it’s common to achieve a 10–20% increase in OEE:
    • Higher Throughput: 10–20% more units produced — with the same amount of time and machines.
    • Shorter Production Times: Or the same output in just 80–90% of the time previously required.
  • Identifying and Reducing Bottlenecks: Shorter lead times, greater flexibility, and improved on-time delivery.
  • Savings from reduced need for special or overtime shifts can have an even greater impact than OEE gains alone, as both machine and labor costs can be sustainably reduced.
  • Resource Efficiency:
    Machines, energy, and personnel are utilized more effectively — reducing not only costs, but also your environmental footprint.
  • Foundation for AI and Data Analysis:
    Collected production data serves as a foundation for data-driven process optimization and AI applications (e.g., bottleneck prediction).

Quality improvement

  • Early Error Detection: An MES continuously monitors production parameters and compares them to predefined tolerances. Deviations are immediately detected and reported, allowing corrective actions to be taken before defective products are made.
  • Less Scrap = More Sustainability: By reacting quickly to deviations, scrap is minimized — saving costs for rework, labor, and materials, while also reducing environmental impact.
  • Process Standardization: MES systems enable the definition of clear quality standards and ensure they are consistently maintained throughout the entire production process.
  • End-to-End Traceability:Every product is fully documented from raw material to finished good. This allows for faster root cause analysis in the event of quality issues, compliance with regulatory requirements, and confident responses to customer inquiries.
  • Preventive Measures: Beyond correcting errors, an MES also helps define long-term preventive actions to avoid recurring issues.

Increased flexibility in production

  • Mastering Production Variants: MES systems simplify the management of variants and custom orders by integrating specific requirements directly into the production process.
  • Realistic Adjustment of Target Times: An MES allows you to validate and adjust target times used in costing and OEE calculations based on actual cycle and setup times. This helps identify profitable and unprofitable jobs more accurately — avoiding unnecessary orders and missed opportunities.
  • Optimization of Batch Sizes and Cycle Times: Especially in the production of smaller batch sizes (e.g., in series manufacturing), an MES helps reduce setup times, avoid rework and overproduction, and ultimately maximize efficiency.

Improving customer satisfaction

  • Improved On-Time Delivery: An MES enables more accurate adherence to delivery deadlines, strengthening customer trust and satisfaction.
  • Higher Product Quality: Continuous monitoring and analysis of production processes result in fewer errors and improved quality of finished products.
  • Stronger Market Position: Companies with optimized processes and high-quality standards are better equipped to compete in the marketplace.
  • Greater Flexibility for Customer-Specific Requirements: The ability to respond flexibly to customer needs enhances long-term customer loyalty.

Energy efficiency

An MES enables a significant reduction in energy consumption through precise plant control and monitoring. Savings in the five-digit range are realistic, as the system collects and analyzes energy data and enables targeted measures to reduce consumption.

Compliance and risk management

  • Compliance with Legal and Industry Regulations: Through complete documentation and traceability, an MES supports compliance with standards such as ISO 9001 and industry-specific regulations (e.g., in the automotive or medical device industries).
  • Minimization of Liability Risks: Full traceability of processes and products reduces the risk of liability claims or product recalls.
  • Audit Readiness: An MES significantly simplifies both internal and external audits by providing centralized access to all relevant data.
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