• Everything for roll manufacturers and converters.

    Everything for roll manufacturers and converters.

    A homogeneous system for all processes in the roller world - COAGO MES for roll manufacturers, converters and for all those who work with rolls, web materials, formats and sheets.
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The integrated and homogeneous solution for your production, formulations, mother rolls, converting, packaging and shipping.

COAGO MES offers sophisticated modules for each phase of the entire value chain of roll manufacturing and converting:
Starting with mixing processes and formulations, alternative formulations and alternative raw materials to production processes of large rolls, mother rolls or tamboure and finishing with converting and refining.

COAGO MES provides a complete scope of modules for modern Manufacturing Execution Systems. This layer of modules is the link between MES- and established ERP- systems, but also a link to the machine level/PLC. All requirements for production and processes accompanying production are met by this layer. Business, machine, process and quality data is gathered and preprocessed. The MES-level supplies information to ERP and other exterior systems.


Production and processes

COAGO MES is used to plan, monitor, control and report on the entire production process and the processes that accompany it. Starting with goods receipt - as an alternative to the ERP system handling - receipt of rolls and raw materials can be processed and reported back to the ERP system. Mixing processes of raw materials (e.g. granulates, pulper, ink and pastes) are transferred to the mixer based on the recipe in the MES. The raw materials used for recipes, alternative recipes and group articles are documented. They serve as a starting point for batch traceability throughout the entire production process. Inventory changes are reported to the inventory management system. The confirmation of the produced mother rolls from the calender, extruder, co-extrusion, paper machine or nonwovens

line takes place in the MES system. Mother rolls are jumbo rolls, reels, large rolls. Each production object (rolls, format blocks) can be uniquely identified by its ID number. Parent rolls are used and consumed for coating, laminating, printing, perforating or stretching (mono- and bi-axial). The new semi-finished rolls are labelled and clearly identifiable. The mother rolls used are reported as consumed. The parent rolls are slit to customer rolls and format blocks (sheets) on the slitter and format cutter and packed on pallets according to the packing styles (packing instructions). Further converting steps such as bag production or punching are also included in the portfolio. Parallel to the manufacturing processes, machine and process data acquisition, quality management and warehouse and logistics management work.








Description of the COAGO MES modules



The PPS module supports both long-term and medium-term rough and fine planning. The visualization in the Gantt diagram takes place on the level of the plants as well as the order. The planning is done with Drag & Drop. Both campaign planning and parallel production planning are supported. In parallel production, matching orders are planned for the machine in a combination order. Both lead to the reduction of set-up times, changeover scrap and residual rolls. Especially when splitting campaigns and orders, the complete rolls to be produced are taken into account. Plans can be saved as scenarios and compared with each other. The best plan is activated and loaded into production. Synchronization with the production data acquisition is done in real time so that the planner can track the production process online on the planning board.
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The entire order and each of its operations in the order network are permanently monitored with regard to their adherence to delivery dates. Deviations and critical states are displayed as symbols in the form of warnings.
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In order to make optimum use of machine capacities and working widths on lines such as extruders, calenders or slitters and to have to store as little waste or residual or edge trim as possible, orders are combined to form a combination order. The confirmations are sent to the ERP system for each order according to the source.
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With the graphic trimming planning several orders can be planned on a mother roll. The machine operator receives a visual and comprehensible trimming plan. Waste is reduced and possible causes of errors are eliminated.
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Inventory information is used as an ERP snapshot to check availability shortly before production starts and is updated during production. If stock is insufficient, the range of coverage is displayed. In the case of overlapping production, the production progress of the preliminary phase is taken into account. The system ensures that the order does not have to be terminated due to a material shortage.
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Shift models can be created as shift plans for each workstation or for groups. Shift changes are carried out in the system according to the shift plan, transfer quantities are recorded and shift transfer information is made transparent.
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The complete recording of quantities and times is a basis for the performance statement in controlling and for continuous improvements (CIP). The entire material input and the entire output are recorded in a qualified manner and returned to the ERP system. On the output side, co-products and by-products are also taken into account. The result is a differentiated picture of yield, blocked quantity and blocking reasons and quantity that does not comply with specifications, e.g. not compliant but still usable in another market segment up to regenerable as raw material or total waste with the respective reasons. The same applies to the differentiated reported times (active time, downtimes, malfunctions, and setup times).
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Data is transferred from sensors and from the machine PLC and projected onto the rolls. This results in a detailed description of the machine operation data during the production process for each roll.
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Data from inline inspection systems, such as optical control systems, are also projected onto the rolls like machine data. Errors are stored as an error matrix. This is the basis, for example, for automatic locking (blocking) of rolls that do not comply with specifications or marking with workflow flags. The specifications are managed in the SPECS module.
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In roll management - the same applies to formats - all rolls produced in the work phase are displayed. When and which operator reported, blocked or rejected the roll and for what reason, whether test results or a text for the roll have already been entered and from which origin roll it was created can be seen immediately. The dimensions of the roll can also be changed here if, for example, the length was changed by cutting down. Validations of weight, length, width and basis weight monitor the correct roll notification.
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A danger detected is a danger less. Particular attention is paid to continuous inspection for quality monitoring. Through the integration of inline inspection systems for the running web, defects are detected, classified and the defect map is projected onto the roll. They are validated according to the valid specification. If warning limits or intervention limits are exceeded, a warning is issued before the specification is violated so that the machine operator can take countermeasures. Should the specification nevertheless be violated, the roll is locked or marked.
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The COAGO MES quality module operates parallel to the process chain along the value-added process from incoming goods to parent rolls, the converting processes and packaging to final inspection and packaging. Inspection plans can be created and differentiated for specific customers, materials or machines. The inspection planning and inspection plan determination logic for the order is rule-based. In the inspection characteristics management, target values, tolerances, warning and intervention limits are defined or determined from the order context.

Sampling procedures for the inspection severity - also dynamic inspection severity - up to 100% inspection are defined in the QM module.

Quality workflows are defined in COAGO, so that in the case of internal complaints every party involved can recognize exactly which activity is required of him.

Inspection results can be recorded manually or transferred from industry-standard inspection devices via interfaces. The acceptance and rejection of individual test results up to the inspection characteristic and the inspected object or inspection point follows defined rules. Violations of tolerances or warning limits are visualized in color.

Analyses and evaluations such as control charts, trend graphs, charts or correlations are carried out in the MES-integrated reporting module.

Test certificates and declarations of conformity can be retrieved directly from COAGO.
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The Track and Trace module in COAGO offers significantly more than just traceability from the customer roll to the raw material used. It enables barrier-free navigation through the entire production process in every direction - multidirectionally. It can be started flexibly at any identifiable point in the process chain. The entire process is visualized starting from, for example, a roll in the lamination in the direction of its origin and consumption.

With "Drag & Drop", each object (raw material batch, production resources, tools, roll, pallet, production order) can be "dragged" into the search window so that the viewing direction always follows the operator's information requirements. Thus, for example, the use of a raw material or a production resource in all affected orders, work steps, rolls, pallets and customers can be determined within seconds.

Drill-downs can be used to branch from the tracking module into further modules, e.g. from the roll on the inspection results, process data or sister rolls. From the Track & Trace module, rolls can be marked with workflow flags or blocked.

The information can be exported for further processing.
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Any plans, e.g. control plans, cleaning plans or line clearance instructions, are stored in COAGO and confirmed by the operator.

The machine operating parameters in the machine setting sheet, the machine parameters for e.g. target values, upper and lower warning and intervention limits, tolerances are stored in COAGO. Depending on the relationship between the machine and the article, the correct best values are determined by means of the plan-finding logic and displayed to the machine operator or transmitted directly to the machine. The actual values from the machine and process data acquisition are validated with regard to the specifications and trigger further actions such as blocks, markings or messages if the specifications are violated.
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Statistical values such as standard deviation, variance, Cp and CpK provide a picture of process capability. The visualization takes place online and on demand, e.g. in charts and histograms as dashboards.
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Roles are marked with workflow flags. These can be release indicators for explicit release, maturing times (e.g. curing of adhesive in the lamination) or minimum best-before dates. Workflow indicators can also be used to mark exceptional situations, e.g. process deviations, recipe changes or resubmissions in the Daily Quality Meeting. The workflow indicators enable multiple marking and easy retrieval of the marked objects. Process-related workflow indicators are, for example, line clearance, print preparation, rework or presence requirements during production, e.g. for trial orders or samples.
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The logistics module controls the supply of the production with material components and the disposal of the goods produced, e.g. to the warehouse or the next production phase. The resulting transport orders are displayed on stacker terminals and confirmed after completion. The complete integration of logistics into the MES ensures that production is supplied with the right material of the right quality at the right time. Material blocking has an immediate effect - from goods receipt to dispatch.
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Transport orders for the supply and removal of production can be entered manually or generated by the system, for example, for kanban areas. Materials available for transport are displayed on roll level or as pallets and can be reserved. Reservations prevent competing access. Storage and retrieval strategies control the inbound and outbound stock movements.
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The ERP system is normally always the inventory management system. COAGO MES does not compete with the ERP system, but transmits inventory changes that are posted in the ERP system. Stocks that are not managed in the ERP system depending on the Customizing settings, e.g. semi-finished goods / WIP, can be managed in COAGO. Stock views and availabilities can also be checked here.
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COAGO supports permanent inventory in order to keep stocks permanently up to date. Key date inventories can also be processed via the inventory module, also for certain areas.
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CONTROLLING - Controlling- and Reporting Modul

COAGO has an integrated reporting module. Reports can be stored as tables or graphical charts in a great variety of visualization variants. The flexible control of the reports is carried out via parameter ranges which the user can define himself, e.g. date from to, machine, machine group, order, material, customer, etc. Thus, a standardized report can be defined user-specifically in a variety of ways. Drill-downs lead to more detailed views. Both the underlying data and the charts can be exported. In addition to accessing reports in COAGO, they can also be used as html in internet browsers.
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DASHBOARD CENTER - Management Information

In the Dashboard Center, CAOGO reports can be prepared in such a way that they have the optimal usability for each management level. Access is made without logging on to the MES system, so that information is available anywhere and at any time.
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LINE DATA DISPLAY - visualization at the machine

All reports can be visualized at the machine. These can be key figures, process diagrams of machine or process data and all other information that helps the operator to optimize his production.
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Planned, preventive and timely maintenance ensures that complex machinery works reliably and optimally. It helps to reduce scrap and downtimes. Maintenance plans and maintenance information can be mapped and integrated both in COAGO and in external solutions. Stress information of machines, machine parts or tools is generated via Shop Floor Data Collection messages for quantities and times. The structured and catalog-based transfer of malfunction reports and damage patterns can be made to 3rd party maintenance systems or ERP maintenance modules.
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PRINTOUT / LABELS - Labelling and Printing

Label printing can be done from COAGO. The integrated routing controls whether and which internal, external or customer-specific labels are to be printed. Labels can be designed with common WYSYWIG layout programs to which the data to be printed is transferred.
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DOCUMENTS - Embedding Documents

Integrated documents such as the quality manual or a machine manual can be addressed and opened directly from COAGO. Jump marks can be used to branch directly from the context at the system to the corresponding chapter, e.g. an inspection instruction for an inspection characteristic. All documents that can be opened in web browser can be integrated.
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SERVICE & ADMIN - Administration

COAGO offers comprehensive administration options for e.g. employee administration, assets, work processes, inspection plans, control plans, time types, groups and codes, shift planning, to name but a few.

The entire application can be controlled via master data settings. Masks can be adapted via styles, areas can be shown or hidden.
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GRASS has comprehensive know-how regarding the design of interfaces for integration with ERP systems. The monitoring takes place by means of transparent interface monitoring and scheduling of the interface transactions.

In quality management, the common QA testing devices used in roll production and converting can be integrated. Please contact us for details.

Interfaces to machine control and process data acquisition as well as to other subsystems such as scales round off the portfolio.
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Grass GmbH
Kreuzstraße 24
55543 Bad Kreuznach
Tel.: +49.671.9289.0
Fax: +49.671.9289.111

E-Mail: info(at)grass-gmbh.de
Web: www.grass-gmbh.de

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