Projects and Experience

A selection of functions already implemented

As a software architect, I can revolutionize the way manufacturing plants operate by providing digital tools that tailored to the specific needs of each production site increase efficiency, reduce waste and enable faster, more informed decisions. It makes me proud when our customers achieve unprecedented levels of productivity as a result.“   

Quote from Stefan Misselwitz, with COSMINO since 2002 


The Recording of the staff requirements during the manufacturing of goods provides information which is useful for the calculation and enables an overview of productivity. In addition to this, the key performance indicator for machines, OEE, is only meaningful in combination with a key performance indicator on productivity. 

A recording of staff times and activities also enables the calculation of performance-based salaries. 

Functions in this area are: 

  • Staff login at the acquisition workplace 
  • Recording of staff time 
  • Administration of staff skills and verification upon login 
  • Record activities of the staff 
  • Calculation of bonus salaries, piecework, group wages, etc. from operational data and their transfer to wage payment tools 

Recording and prompt reporting of data to the ERP supports the inventory management in the ERP and enables for the subsequent costing of orders. 

  • Record of order change 
  • Record quantity data 
  • Manual correction of quantities 
  • Manual and automatic shift change 

High standards of traceability require a comparison of the order processing with the planned bill of materials. However, this may also be required for the inventory management if a retrograde inventory entry of material consumption per quantity unit is not sufficiently accurate. 

  • Batch recording 
  • Display of the bill of materials at the acquisition workplace 
  • Recording of material consumption bill of materials 
  • Recording of material batches bill of materials 
  • Entering other consumable material 
  • Record scrap and NOK of bill of materials components 

The meaningful processing of recorded machine data enables the reduction of set-up times, waiting times and other downtimes, and leads to an increase in efficiency in production. This data can also be used for “machine learning algorithms” and predictive analysis (Big Data). 

  • Record workstation/machine state 
  • Diagnosing of this state with a loss type/a reason for error 
  • Recording performance losses/cycle slowdowns 
  • Separate consideration of mini stops, e.g., diagnosing at the end of the shift by multiple selection 
  • Alarming options depending on loss type and duration 
  • Recording and limit value monitoring of process characteristics 
  • Recording of energy consumption 
  • Analysis of process and energy characteristics 
  • Generation of key performance indicators on energy (EnPI, energy footprint, status-related consumption, etc.) 

The recording and analysis of the use of tools allows for the optimum tool lifetime to be achieved at production plants, which enables tool costs, changing times and unplanned tool changes to be reduced to a minimum. It also enables compliance with maintenance intervals and set-up optimization. 

  • Tool management with tool parts list 
  • Record tool usage and tool lifetime 
  • Determine tool costs 
  • Recording tool changes with reason 
  • Changing of the yield in the case of multi-component tools 
  • Recording of quantities in the case of multi-component tools (also in the case of a changed yield) 

In-process quality inspections on the product are a fundamental part of the zero-defect strategy – they ensure the customer satisfaction. The sooner a defect is detected in the process, the fewer costs arise. High quality also supports customer satisfaction. 

  • Worker self-check 
  • Attributive recording of defects according to type of defect 
  • Defect recording on product image 
  • Bidirectional integration ERP 
  • Own inspection planning and import options for inspection plans
  • Inspection order administration
  • Inspection can be triggered automatically (e.g. every X quantity or time units) or manually
  • Modern and user-friendly data acquisition dialogues
  • Digital control chart directly at the acquisition workstation
  • Digital inspection instructions, documents etc. for each inspection
  • Optional acquisition of measures during NIO inspection and subsequent repeat inspection
  • Optional acquisition of quantity, e.g. for sorted quantities at NIO
  • Export of the recorded data to qsSTAT or Minitab for analysis
  • CPK-dependent test severity control

Meaningful key performance indicators create transparency and facts. Previous discussions on reports can be dispensed with, creating time for the actual improvement process. This also applies at the workplace, where the precise information which is actually needed should be available at a given moment in time (and no other information). 

  • Shopfloor management 
  • Calculation of key performance indicators, e.g., OEE 
  • Generation of evaluations of key performance indicators and operational data 
  • Correct generation of histories in reports, even if master data has been changed in the meantime 
  • Visualization of key performance indicators and operational data in real-time 
  • Distribution of real-time data (and histories) to other systems 
  • Display of event-related documents 
  • Read confirmation for documents 

Scheduled maintenance increases the tool and system availability and reduces downtimes and poor quality. 

  • Monitoring of infinite counters, such as quantity and production time per machine 
  • Scheduling of maintenance activities in the calendar 
  • Display of maintenance activities in the entry dialog 
  • Recording whether the maintenance has been carried out 
  • Recording the duration of the maintenance 
  • Scheduling of checklists 
  • Retrieving checklists in the data entry dialog 
  • Scheduling of audits 
  • Performing audits 
  • Calculation of the audit results 
  • Recording of improvement measures 
  • Operational suggestions management 
  • Process workflow for improvement measures and suggestions 

Traceability enables the journey of a traced unit through the manufacturing process to be documented. This means that times, processes, operational data, order, system parameters, inspection results, intermediate products, input materials, tools and further information are unambiguously assigned to a traced unit. 

The manufacturing process itself is known to the system, which means that further tasks and safeguards can be triggered on the software side. 

  • Booking of individual units (batches, parts, etc.) through 
  • Processing steps 
  • Booking of individual units (batches, parts, etc.) in 
  • Carriers 
  • Individual workflows for each article (from where to where and when an article can be entered) 
  • Consideration of quality in the workflows (rework loops, etc.) 
  • Recording of the quality status per individual unit 
  • Transfer of the quality status from inspection systems 
  • Management and historically correct mapping of the quality status per individual unit 
  • Product-dependent workflows through all processing steps 
  • Workflow switches, e.g., for rework 
  • lock parts management 
  • Triggering of print activities in the process 
  • Triggering of read activities in the process 
  • Triggering of transports between workflow steps and storage 
  • Triggering of material requirements for workflow steps 
  • Triggering of processing activities in the process 
  • Triggering of variant-dependent processing activities in workflow steps 
  • Transfer of default and setting parameters in workflow steps 
  • Transfer of implementation parameters 

In the case of product-dependent work steps, at least at work centers with lot size 1 or higher variance, a worker guidance is required which shows the necessary activities to the employees and requires a manual or automatic confirmation of the various steps for the traceability. 

  • Step-by-step guidance of the worker through the machining process at the workstation (e.g., for assembly) 
  • Variant-dependent processing steps 
  • Quality-dependent processing steps (e.g., reworking) 
  • Guided commissioning 
  • Recording and checking the serial, batch and material numbers of installed components 
  • Detection of faulty processing steps or components 
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