Bringing information to light

GC2 Manufacturing Execution System (MES) , developed by GC2 is designed primarily for the Mining, Beneficiation, Smelting, Engineering, Manufacturing and Natural Resources industries. GC2 delivers a cost effective, world-class system and service providing clients the means to manage accurate information throughout the organisation.

GC2 MES combines various modules to create a holistic view of manufacturing and engineering processes. GC2 use the latest technologies to deliver simple, powerful and affordable business management software.

MES - Complete control in one integrated system

GC2 MES integrates with any plant control equipment and operational management solutions e.g., SCADA, Historian, PLC, Weighbridges and Lab Analysers to create a holistic view of manufacturing and engineering processes through the following system modules and functionality:

The material handling and tracking module monitors, manages and reconciles the movement of materials and the stockpiling thereof. It provides real time information with regards to the quantity and quality aspects of the materials. It is highly configurable and can be customised to suit individual requirements.

The system requires very little human intervention and automatically acquires data from real-time control systems and or external weighbridge systems. It is tightly integrated to the LIMS module and external ERP system. This provides enhanced analysis of historical data and notifies ERP Systems or other external systems of inventory and quality changes.

Any manual operations can also be carried out using the web based front end. Each user owns an interface, protected by security mechanisms such as a login and a password. This offers a high level of security and privacy of data. Users have customized interfaces based on their role description. A production manager might have full access to the system, whereas services operator might have access only to functionality needed for their individual work-tasks.

The Material Tracking is a very rich application providing functionality for:

  • Weighbridge Automation and Integration
  • Raw Material Purchasing
  • Raw Material Stockpile Management
  • Raw Material Quality management
  • Raw Material Consumption
  • Plant Production
  • Final Product Stockpile Management
  • Final Product Quality management
  • Sales Order Dispatch
  • Manufacturing Execution System & Integration to Plant Historians

The Laboratory Information Management System (LIMS) module is used in the laboratories for the management of samples, laboratory users, instruments, standards and other laboratory functions such as workflow automation and generating certificates of analysis.

Because the system is web-based it requires no special client-side installation, thus allowing accredited users the opportunity to see analysis results in real time from any web browser and from any operating system.

It can be configured to be used by an unlimited number of users. Each user owns an interface, protected by security mechanisms such as a login and a password. This offers a high level of security and privacy of laboratory data. Users have customized interfaces based on their role description. A laboratory manager might have full access to the system, whereas technicians might have access only to functionality needed for their individual work-tasks.

The system is endlessly configurable and can incorporate new functionality quickly and with ease. The LIMS module is uniquely designed in that it leverages off the other modules thus providing the organization not only with result information but an integrated view of quality per manufacturing process. This includes:

  • Stockpile Quality Control based on Weighted Average Analysis
  • System, Email, and SMS notification when sample results are out of Specification
  • Mass Balance analysis from product to element level

The LIMS module automatically extract and save data from analysis equipment (e.g Spectro ICP, Eltra C/S etc.), thereby reducing the risk of faulty results transfer and ensures fast turn around times for samples. It further allows for the generation of certificates of Analysis with integrated electronic authorization and distribution workflow.

The Downtime module enables proactive management of company assets and the discovery of the areas most likely to negatively impact plant production and performance. By identifying problem areas, we unlock the key to consistent asset performance.

The Downtime module is designed to automate the monitoring and analysis of downtime events resulting in a more accurate reflection of lost production and of possible problem areas.

Because the system is web-based it requires no special client-side installation, thus allowing accredited users the opportunity to see downtime events and subsequent reporting from any web browser and from any operating system.

The Downtime module is uniquely designed in that it integrates to real-time control systems ensuring that the downtime event is recorded at instrument / equipment level. This ensures accurate time keeping of the event. The operator characterizes the event by selecting from a predefined list of possible reasons. These reasons are fully configurable to three drill down levels by the plant engineers and are designed to identify problem areas.

The system is endlessly configurable and new plant sections can be incorporated quickly and with ease.

Log Sheets are Configurable per Customer Requirements and Plant Operators enter and monitor Key Performance Production Indicators in real time.

The Mass Balance module can enhance the knowledge on the current process state and thus support optimized process operations by providing additional input data for process control. The system measures the material flow into and out of various production units. This information combined with the sample information enables the system to do mass balance calculations to element level. These calculations can be done through any production unit.

The Sales and Export Management module is an odd-on module in the MES solution that can be configured to the customer’s requirements and contain following functionality:

  • Order & Sale Processing (Including Sales & Inco Terms)
  • Information Capturing (Shipping and Export Information)
  • Shipping Instructions
  • Sales, Cost & Information Processing (Provisional)
  • Generating Provisional Sales Documentation (Consignment Sheet & Commercial Invoice)
  • Actual Cost Input & Calculations (Local and Foreign Cost)
  • Final Sales and Cost Processing (Sales, Weight, Price, Analysis & Costs)
  • Generating Final Sales Documentation (Consignment Sheet, Final Accounting, Final Commercial Invoice)
  • Sales and Export Reports
  • System integration to ERP (Provisional, Final and Amendment Journals)

Real-time and historical data can integrate with MS Excel and other required formats. This functionality allows proficient Microsoft Excel users to generate their own reports.

Integrated Reporting Engine through Crystal Reports and Microsoft SQL Server Reporting (SRS). Reports are viewable via the web interface or exported to Adobe PDF or Microsoft Excel.

Reports scheduler and Email/SMS notifications are configured to run at predefined times or events.

Users are authorised to subsets of data and functions corresponding to the assigned profiles.

The number of profiles and associated security levels are totally configurable.

Transactions are configured where appropriate to include approval and escalation levels.

The system allows for full automated integration to any ERP solution using integrated web services, direct system interfaces and API.

The system also caters for user managed integration to any ERP through journal processes.

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Key benefits of GC2 MES

Why GC2 MES?