Since its establishment in 1958, Kayalar Copper Alloys San. ve Tic. A.Ş. has been one of Türkiye’s leading manufacturers, producing sheets, strips, coins, and tokens from copper and copper alloys by focusing on technological advancements and high-quality standards.

As part of the Production and Energy Monitoring Project, Pro-4 IoT Platform has been successfully implemented to monitor and report the rolling, furnace, and continuous casting processes along with energy consumption metrics. This comprehensive solution aims to enhance operational efficiency and provide seamless data-driven decision-making.

Key Features of Pro-4 IoT Platform

1. Real-Time Monitoring:
   • Instant Data Collection: The platform collects data from machines, sensors, and equipment across production lines, enabling operators and managers to monitor processes in real time and respond to inefficiencies immediately.
   • Production Process Visualization: Advanced graphical interfaces allow users to track production status at every stage, quickly identifying disruptions or performance drops.
   • Support for Multiple Production Lines: The platform provides holistic production management by monitoring multiple lines simultaneously.
2. Advanced Data Analytics:
   • In-Depth Analysis: The platform analyzes machine performance, bottlenecks, and operational efficiency using advanced analytics.
   • Trend Detection & Anomaly Identification: It forecasts potential equipment failures through trend analysis, allowing proactive maintenance to minimize downtime and ensure continuous production.
3. Comprehensive Reporting & Visualization:
   • Customizable Reports: The platform offers flexible modules for performance evaluations, energy consumption analysis, and error reports, tailored to users’ needs.
   • Visual Data Presentation: Data is presented through charts, graphs, and dashboards to simplify complex information and facilitate quick decision-making.
   • Historical Data Storage: Users can access historical data for performance evaluations and export reports in various formats such as PDF and Excel.
   • KPI Monitoring: The platform tracks key performance indicators (KPIs) and monitors progress toward production targets.
   • Energy Monitoring: By tracking energy consumption, the system helps improve efficiency and reduce operational costs.
4. Automated Alerts:
   • Critical Event Notifications: When predefined thresholds are exceeded, the system sends alerts to operators, maintenance teams, and managers.
   • Flexible Alert Management: Alerts can be customized and delivered through email or in-app notifications.
5. Operational Efficiency Tools:
   • Data-Driven Decision Making: The platform supports decision-making processes with actionable insights based on collected data.
   • Resource Management: It optimizes the use of energy, materials, and human resources, reducing costs and increasing profitability.
6. Integration & Compatibility:
   • Multi-Device Integration: Pro-4 IoT Platform works with machines of various brands and models, ensuring seamless integration into existing production lines.
   • ERP/MES Integration: The platform integrates with ERP and MES systems, enabling smooth data flow across multiple systems.

Conclusion

The Pro-4 IoT Platform plays a critical role in digitizing production processes by increasing efficiency, reducing costs, and optimizing operational performance. Beyond monitoring current operations, the platform offers valuable data for future decision-making, ensuring continuous improvement and competitiveness. With this successful implementation, Kayalar Copper has taken a significant step toward smarter production management.

At NOVA ELEKTRİK, which operates in the white goods sector, our project for online and automatic data collection from over 150 machines has been successfully delivered.

In this project, real-time production data is collected from the machines, ensuring seamless traceability of all processes. Additionally, the MES (Manufacturing Execution System) software has been successfully implemented, contributing to the digitalization of operations.

Furthermore, ERP integration services have also been provided by GNC Proses, ensuring data integrity and workflow alignment between the production and enterprise resource management systems. As a result, production efficiency has been enhanced, decision-making mechanisms have been strengthened, and manual processes have been minimized.

Category: MES

Date: 2021

At Kutaş Ambalaj, a leading company in the packaging sector, our MES Manufacturing Execution System project was successfully completed to enhance production processes and increase efficiency.

Within the scope of the project, GNC Proses provided the following:

1. MES System Installation:
   • Real-Time Production Monitoring: The MES system enables real-time tracking of data from the entire production line, ensuring every step of the process is easily monitored.
   • Improving Production Efficiency: Operator performance, production targets, and machine efficiency were analyzed to optimize workflows.
   • Minimizing Production Errors: Data from the production line is analyzed in real-time, allowing early detection of issues and timely interventions.
2. ERP Integration:
   • Seamless Data Flow Between Systems: Integration between the MES and ERP systems ensures that all production data flows into the ERP. This integration improves processes like material management, stock control, and production planning.
   • Automation of Operational Processes: Automated data transfer reduces the need for manual input, minimizes human error, and accelerates decision-making processes.

Outcome:

With this project, production processes at Kutaş Ambalaj have become more transparent, measurable, and efficient. The integration of MES and ERP systems has improved operational processes while reducing costs.

Category: MES

Date: 2023