TRAC-IT MES - With Murray Hilborne (MARCO MD)
Murray Hilborne, Marco Ltd
What actually is TRAC-IT MES ?  
TRAC-IT MES is a powerful and highly versatile factory floor efficiency system. In essence MARCO's MES (Manufacturing Execution System) is a blend of 'operational specific' software modules, which are then customised to meet the exacting demands for each part of the manufacturing process. The System envelops all Key Performance Locations from Goods In to Goods out. These include Stock Management; Recipe Control; Production Scheduling with Yield Analysis and In Line Code Validation with the focus on Traceability throughout.
Where does TRAC-IT MES fit within the overall manufacturing process ?
Fitting between the factory floor control systems at one end of the spectrum and business systems at the other, the TRAC-IT MES layer effectively controls the 'who, what, where and when' of such operations by recording, analysing and responding to factory floor data in real time. There is a large amount of data generated through factory information systems, which is critical to a business' success. However, due to its complexity this data is often ignored and the role and success of TRAC-IT MES emanates from converting this data into real time information so that management can exploit its full potential.
Why is there a need for TRAC-IT MES - surely ERP programs such as SAP fulfil all the manufacturing requirements from the factory floor up?
Although ERP systems play an important role in modern manufacturing environments, they often do not make best use of the rapidly changing factory floor data. For instance ERP systems are renowned for creating what has become known as 'unaccountable losses' and these anomalies are clearly detrimental to any operation. ERP vendors tend to promote 'top-down' integration but struggle as they near the factory floor. We believe that as an MES provider, we have a better view of the manufacturing process by promoting a floor-up approach. Although ERP vendors have endeavoured to introduce MES tools, information from the factory floor is still at best under-utilised. Our experience shows that a well implemented MES unlocks the potential of ERP allowing systems to react to actual information rather than historic data.
You use the phrase 'unaccountable losses' - where do these come from and how does
TRAC-IT MES resolve them ?
Consider a company manufacturing their products from pre-defined recipes. ERP systems normally work on preset targets for the batches, assuming these are met - precisely. Under normal circumstances they have no real-time information to contradict this assumption: the stock is downgraded by this amount and costings calculated accordingly. However what happens if the amount used is slightly above the target as is typically the case? The first time management may become aware of these 'target excursions' is when stock checks are done and the inevitable stock inconsistencies come to light. By then it's usually too late to carry out any meaningful analysis to find out what went wrong and the 'unaccountable losses' then become an 'expensive reality'. In contrast TRAC-IT MES works on actual weight data, recording and analysing every actual target weight so that accurate stock movement is recorded. Moreover the modules within the system are specifically designed to minimise target excursions.
MES is not a new concept yet companies within certain industry sectors have been
slow to take it up. Why do you think that is ?
We find that companies are unclear on the benefits and ROI for an MES. If they've invested heavily in what they believed to be an all-encompassing ERP system, understandably they are reluctant to spend more on an MES without fully understanding the cost and time implications. When approaching a new client, we spend considerable time understanding their operation and existing systems before setting out our proposal. Every proposal is accompanied by an agreed justification section laying out the cost saving benefits with some tangible monetary values wherever possible. This ensures both parties fully understand what is expected. TRAC-IT MES is highly flexible and if applicable can be implemented in modules stage at a time, allowing clients to understand and appreciate the benefits.
What are the main differences between a traditional MES and TRAC-IT MES ?
Manufacturing Execution Systems have been developed by traditional software suppliers with minimal 'hands on' experience in actual factory floor processes. By comparison, MARCO's roots are in weighing, which forms an essential part of many manufacturing operations. As we developed our equipment we identified the need to integrate real-time weight data into overall management systems but in the absence of suitable software modules, we had to start developing our own. Our award-winning TRAC-IT MES is the result of over 20 years hard-won experience in factory floor systems and this, we believe, sets us apart from other MES suppliers.
Why is the Marco approach different to traditional software houses ?
We look at the process first and the integration second. Once we have understood the macro and micro detail of a company's process, we can tailor our system to provide optimised operational equipment effectiveness. We can also take responsibility for the supply, installation and commissioning of all the essential factory floor equipment, working closely with our clients to ensure seamless integration.
What benefits do TRAC-IT MES bring to the food industry in particular ?

Modern food manufacturing is a unique, complex and fast-paced environment. The complexities of working with finite shelf-life products and rapidly changing customer requirements set it apart from other industries. TRAC-IT MES is ideal for such environments, especially in the ready meals, snack and soft fruit packing sectors. These are still highly dependent on manual assembly and as a result maintaining efficiency, whilst minimising expensive giveaway can be a complex scenario. Add to this the growing legislation and customer expectations, and without adequate control you could have 'a recipe for disaster'. By capturing data every step of the way, we can continually fine tune processes through proprietary technology such as Automatic Optimisation applied to portion control. TRAC-IT MES takes control of all the processes thereby ensuring that customers 'keep their finger' on the pulse of their business.
What is 'Automatic Optimisation' and how does it help reduce giveaway ?
Automatic Optimisation (AO) is an ingenious software module within TRAC-IT MES which continually adjusts target weights based on actual operator performance. This is a prime example of how our system has been developed based on practical operational problems. Real time data from equipment including check-weighers and portion control scales is continually used in a feed back loop to automatically adjust the target settings so that the average giveaway is radically reduced, whilst still ensuring factors such as nutritional values and packaging legislation are maintained.
What is a typical payback period for companies investing in TRAC-IT MES ?
In many applications, the ROI has been remarkably short especially in the ready meals and soft fruit packing sectors. When companies are producing millions of meals per annum, even modest reductions in giveaway have a major impact on bottom line profitability. We believe that the disappointing ROI attained from ERP systems, in many cases, is down to lack of accurate factory floor data. TRAC-IT MES brings a measure-control-improve ethos to companies and is designed for the long-term sustainable solution, not a short term fix. Typically the payback period is less than 14 months from commissioning and implementation.