Latest large scale installation of Logikal MES at AMS in Cork

Forterro has just completed its largest scale Logikal MES software installation yet at AMS (Architectural Metal Systems)’ 400,000sq ft production facility in Cork, as the aluminium specialist invests in digitalising its fabrication operation.

Forterro’s Logikal MES system, integrated with its market leading Logikal aluminium processing software, gives fabricators complete control and traceability of their production flows so that they can optimise efficiency and minimise errors.

At AMS, the new Logikal MES software is running parallel production flows through three clearly defined fabrication production routes, with multiple machining and assembly stations all part of the same software framework.

Daniel Hodges, Sales Team Lead at Forterro who was responsible for the installation, explained the significance: “This was bigger and more complex than the previous Logikal MES installations we’ve carried out in the UK and Ireland and perfectly demonstrates both the capability and scalability of the software.

“AMS has a main, high volume production route for windows, doors and curtain walling and additional dedicated routes for sliding doors and bespoke doors for data centres. For the first time, our Forterro Logikal MES software is controlling and tracking each of these diverse routes separately, while maintaining consistent methods of execution throughout the fabrication processes.

“The software is automatically capturing the start and end of every operation at AMS via bar code scanning, with screens delivering clear process instructions for the operators as work progresses down the lines. Each of the assembly steps is also under FPC (Factory Process Control), and AMS has successfully migrated its existing production QC process over to the new facility.”

The new Logikal MES installation allows the production team at AMS to plan for different operations and different volumes on each line and have access to the same level of communication and visibility for all of them. It is also delivering robust traceability and documentation of the process to help demonstrate compliance for both FPC and ISO9001 audits.

It will provide benefits in terms of communication as well, with the system set up to confirm the production of customer-ready identification labels and paperwork at specific assembly points where product completion is confirmed, rather than just at the end of the lines. This ensures right first time product identification, and minimises the gap between build completion and customer-ready dispatch, reducing the risk of missing labels and any last-minute admin.

Damien Farrelly, Fabrication Manager at AMS added: “As a business committed to continual improvement, our investment in Forterro’s Logikal MES is all about optimising efficiency, accelerating workflows and minimising the potential for errors. Digital feedback from every one of the stations around the factory is available in real time via the Logikal MES dashboard, which means we can see who did what, when and where and we can control sign-off at assembly and dispatch. It is giving us a new level insight into all three of our production lines, which I am sure this will help us make even better informed decisions in the future.”

Logikal MES is an advanced software solution from Forterro that integrates seamlessly with the LogiKal aluminium processing software, providing fabricators with complete visibility of their production – from material optimisation through to identifying and managing manufacturing deviations. It displays real-time tracking of jobs, order status, errors and solutions and allows for centralised control and reporting via the integrated dashboard.