Digital manufacturing ecosystem connecting production, logistics, quality, and monitoring through centralized shopfloor software.

How to Select a Line Control System for Modern Manufacturing

Discover how to select the perfect Line Control System (LCS) for your manufacturing operations. This article outlines 7 crucial criteria to help you choose the ideal Line Control System to optimize your production.

Shopfloor Expert

Reading time: 5 min

Best Practice

Criterion 1: Integration Capability – Seamless Connection in the Digital Factory

  • Significance: An Line Control System rarely operates in isolation. It must seamlessly integrate into the existing IT landscape.
  • Aspects:
    • ERP Connectivity: Automatic transfer of order data and material availability.
    • MES Connectivity: Data exchange with the Manufacturing Execution System for detailed production orders, feedback, and quality data.
    • Machine and Equipment Connectivity: Interfaces to PLC controls, sensors, and robots for real-time data and control.
    • Open Interfaces: Support for standards (e.g., OPC UA, MQTT) or easily customizable APIs.
  • Questions for Selection: What interfaces does the system offer? How complex is the integration into our existing infrastructure?

Criterion 2: Scalability and Flexibility – Growing Without Hindrance

The classic automation pyramid in conjunction with STIWA's functions and areas of focus.
Automation pyramid illustrating STIWA's areas of focus: PLCs, production systems, HMI/SCADA, and MES functions.
  • Significance: Production environments are constantly evolving. A good MES software must be able to adapt and grow with them.
  • Aspects:
    • Line and Plant Growth: Can the system easily integrate new production lines or machines?
    • Feature Expansion: Is the system modular, allowing for the addition of future functionalities (e.g., AI-driven optimization, predictive maintenance)?
    • Adaptation to Process Changes: How easily can production workflows, sequences, or work instructions be configured and adjusted within the system?
  • Questions for Selection: Is the system future-proof? Can we adapt it to our changing requirements without having to replace the entire system?

Criterion 3: Real-Time Visibility and Intra-Line Logistics – Keeping Production Flowing

Mobile device displaying production data for real-time manufacturing monitoring.
Illustration of mobile access to production information, KPIs, and manufacturing processes from anywhere.
  • Significance: The ability to collect, analyze, and clearly display real-time data is at the heart of any effective Line Control System.
  • Aspects:
    • Data Acquisition: Automatic capture of process, quality, and machine data.
    • Dashboards and Visualizations: Clear, intuitive presentation of KPIs (OEE, cycle time, utilization), current production status, and disruptions.
    • Alarm and Notification Systems: Immediate information in case of deviations or problems.
    • Reporting: Flexible reporting functions for historical data analysis and performance evaluation.
    • Recipe Management: Real-time access and management of production recipes and parameters, ensuring correct process execution.
    • Intra-Line Logistics: Precise control over part status, component feeding, and order execution within and across production lines, rework management, and recipe management.
  • Questions for Selection: How up-to-date is the displayed data? Are the dashboards customizable to our needs?

Criterion 4: User-Friendliness (UI/UX) – Acceptance and Efficiency on the Shopfloor

Manufacturing dashboard displaying production KPIs, alarms, and machine performance.
Interactive dashboard providing real-time production monitoring, machine status, alarms, and key manufacturing indicators.
  • Significance: Even the most powerful Assembly Line Control software is useless if it cannot be adopted or operated by shop floor employees.
  • Aspects:
    • Intuitive Operation: Easy navigation and clear display for operators, shift leaders, and production managers.
    • Customizable Interfaces: Ability to tailor relevant information for different user roles.
    • Low Training Effort: Short onboarding times for new employees.
    • Supported Onboarding: Affordable training programs and well-thought-out rollout strategies to ensure that everyone is on board.
    • Error Minimization: Well-designed UI/UX reduces operational errors.
  • Questions for Selection: Is the interface clear and easy to understand? What is the feedback from current users?

Criterion 5: Functional Scope and Customizability – Tailored Solution for Specific Requirements

Operator monitoring production using a tablet directly on the shop floor.
Digital production management using mobile devices to monitor machines, production orders, and manufacturing performance.
  • Significance: Every production has its unique characteristics. The Line Control System should be able to reflect these.
  • Aspects:
    • Core Production Control:
      • Order and variant management
      • Material flow and supply management
      • Intra-line logistics for managing and tracking materials and components
      • Machine control and process data acquisition
      • Recipe management
      • Cycle time monitoring and optimization
      • Quality data management and documentation
      • Traceability of products and components
      • Error management, fault detection, and alerting
      • Performance analysis (e.g., OEE calculation or automated downtime detection)
      • Digital work instructions and worker guidance to support shopfloor personnel
    • Specific Industry Requirements: Consideration of industry-specific standards or processes (e.g., batch management in process industries, variant production in the automotive sector).
    • Customization Options: Can the system be adapted to specific workflows, logics, or calculations?
    • Modularity: Does the system only offer the necessary modules to reduce complexity and costs?
  • Questions for Selection: Does the system cover our core processes? Can we map specific peculiarities of our production?

Criterion 6: Support, Maintenance, and Updates – Long-term Partnership and Reliability

  • Significance: A Line Control System is a long-term investment. The provider's support is crucial for smooth operations.
  • Aspects:
    • Support Availability: Response times, accessibility, multilingual support.
    • Maintenance and Service Contracts: What is included in the service package (updates, patches, hotfixes)?
    • Update Strategy: How often and to what extent are new versions and features provided? Is every update a project from scratch or a simple update?
    • Documentation and Training: Comprehensive documentation and training offerings for key users and administrators. View Training Options
  • Questions for Selection: How reliable is the provider? Are there reference customers who can confirm the quality of their support?

Criterion 7: Security and Compliance – Protection for Data and Processes

  • Significance: In times of increasing cyber threats and stringent data protection regulations, the security of the Line Control System is of paramount importance.
  • Aspects:
    • Data Security: Access controls, encryption, backup strategies.
    • Operational Reliability: Redundancy concepts, emergency systems to ensure continuous operation.
    • Audit Trail: Traceability of all changes and actions within the system.
    • Compliance: Adherence to relevant industry standards and data protection regulations (e.g., GDPR, NIS-2, CRA).
  • Questions for Selection: How does the system protect our production data? Does it comply with all relevant security standards and regulations?

STIWA Advantage: STIWA Shopfloor Software meets these key criteria and offers a robust, flexible shopfloor solution. Our system enables seamless integration into existing IT landscapes and ensures scalability for future growth. You’ll benefit from easy integration in greenfield projects through pre-built modules and a powerful low-code platform for brownfield projects. With advanced real-time data processing capabilities and intuitive usability, it empowers your shop floor team. We provide a comprehensive feature set with a high degree of customization, backed by dedicated support and a strong commitment to security and compliance, to guide your company on the path to successful digital manufacturing.

 

Take the next step towards optimized production: Contact us to discuss your specific needs or to schedule a personalized demo of Shopfloor Software. Let STIWA Software help you optimize your production and secure a lasting competitive advantage.
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