Mannin Systems / Process control
Process control, built on your own checks
The checks you already do, built directly into the system and collected from day one. Downtime, scrap and quality measured where they happen, so improvement is based on facts rather than memory.
Runs on the PCs and phones you already have, with site-locked access.
What isn’t monitored correctly can’t be truthfully controlled.
Most small factories do check their work. The trouble is what happens to the checks: a sheet on a clipboard that nobody reviews, a weight written down at the end of the shift, downtime rounded to “about an hour”. The information exists, but it can’t be trusted, compared or acted on.
Mannin Systems captures it at the moment it happens, at the station, in the same place work is booked. That’s what turns checking into control.
Your checks, built in from day one
No two factories check the same way, so we don’t give you ours. At the site assessment we collect your current check sheets, limits, reason codes and quality procedures, and they’re built straight into your system.
- First-off approval
- The first good part or length signed off by the right person before the run continues.
- In-process checks
- Weights, dimensions and visual checks, prompted every so many metres, parts or minutes.
- Limits and reactions
- Each reading checked against its limits as it’s entered, with your reaction plan shown when it’s out.
- Automatic holds
- An out-of-limit result can hold the lot or bundle straight away, until quality releases it.
- Customer requirements
- Checks and limits specific to a customer or product, applied automatically to their jobs.
- Gauges and calibration
- Each gauge recorded with its calibration due date, and flagged before it lapses.
An example of how checks and charts could be set up for an extruder. Every system is built around your own checks and reason codes.
Start today with our free OEE and downtime tracker for Excel
Try it in the working demo: run a check at Line 1, then see it under Quality
Measured where it happens
Because output, scrap, downtime and checks are all booked at the station, the measures you need are worked out from real events rather than estimates.
- Downtime by reason
- Every stop, in real minutes, against your own reason codes and the machine it hit.
- Scrap by reason and station
- Where waste is created, why, and what it costs in material.
- First-pass yield
- How much is right first time, by product, line and shift.
- OEE
- Availability, performance and quality, calculated from what was actually booked.
- Changeover times
- Actual against target for each changeover, so improvements can be measured.
- Trends and run charts
- Readings over time against their limits, so drift is seen before it becomes scrap.
Built for continuous improvement
TPM and kaizen only work when you can measure the starting point and prove the result. The same data that runs the factory does both.
Total productive maintenance
Keep machines running by catching problems early.
- Daily start-up checks at each machine: clean, inspect, lubricate
- Planned maintenance points by runs, hours or metres
- Breakdowns logged with cause, fix and time lost
- Mean time between failures and to repair, worked out for you
Kaizen and improvement events
Make every improvement provable, and make it stick.
- A baseline taken from real data before the event
- Actions recorded with owners and due dates
- Before and after, measured on the same terms
- Trends afterwards, so you can see whether it held
Non-conformance and root cause
When something goes wrong, deal with it properly once.
- Concerns raised at the station, straight from a check
- Containment linked to the lots affected, through traceability
- Root cause and corrective action recorded against the problem
- Customer complaints traced back to the run that made them
Process control questions
Do we have to change our check sheets?
No. We build in the checks you already do, with your limits and your wording. Once the data is coming in, it often shows which checks matter most, and you can refine them whenever you like.
How soon do we get useful figures?
From the first day it’s used. Every check, stop and scrap booking is recorded as it happens, so trends build from day one rather than from a month-end spreadsheet.
Does it help with ISO 9001 and customer audits?
It gives you the records auditors ask for: time-stamped checks, who carried them out, holds and releases, non-conformances and corrective actions, all traceable to the lots involved. The certification itself stays with you and your auditor.
Can it calculate OEE?
Yes. Availability, performance and quality are worked out from the downtime, output and scrap booked at each station, so the figure reflects what actually happened.
Can it connect to our machines?
Many small lines get everything they need from bookings at the station. Where a machine has counters or signals worth capturing, we can look at connecting it as part of your build.
Tell us what you're running on now
A few lines about what you make and how you plan production today is plenty to start with, or simply ask for an introductory call. You'll get a personal reply.