smart factory

Introducing Vortex™ by Equation1

Revolutionary Production Dispatching for Greater Operating Efficiencies

 

Equation1 Vortex™ brings a revolutionary dimension to production dispatching by embedding patented time-based demand-pull intelligence into the production environment reducing cycle-times, WIP inventories, quality costs, factory space and waste while improving sustainability.

Unprecedented Improvements in the Complex Production Environment

 

The Vortex™ platform is a highly compact, advanced and feature-rich dispatching solution that delivers unprecedented improvements in the complex production environment, e.g. highly-variable workflows and/or product mix.

Benefits of a Kanban System for Complex Non-Repetitive Production

 

Vortex™ is an on-premise solution that delivers the same benefits to complex-production companies that the Kanban system does for repetitive-production companies. It’s about time!

Leverage your Smart Factory to Reduce Execution Costs

 

Coupled with AI capabilities, Vortex™ delivers the industry’s highest ROI dispatch-automation solution for total cost and waste reduction in the complex-production environment.

Vortex™ Solution Architecture

rtdp schema 24i

Key Features

  • Real-Time Demand-Pull

    Vortex™’s proprietary time-based demand-pull solution determines when a Work Center will need more work that is currently authorized – its “Need-Time” – then looks upstream at all its feeder Work Centers and identifies the highest-priority, unauthorized Work Order. It then calculates the Work Order’s time of arrival if immediately authorized – its “Arrival-Time” – and authorizes it for production if the Arrival Time ≥ Need Time. This method of dispatching assures that the Work Order arrives at the focal Work Center at the exact time it is needed. Real-time demand-pull automatically minimizes Work Center queueing.

  • Real-Time Demand-Pull

    Because Vortex™ only works upon Work Center pairs, it will accommodate any multiple of, and any type or form of workflows, even the most convoluted and re-entrant workflows. Our most interesting and passionate fans are in the Semiconductor Fabrication industry, which has never had access to demand-pull dispatching until now. It's about time!

  • Auto Line-Balancing

    One unique, and critically important, characteristic of demand-pull dispatching is that it works to automatically minimize queues and level the work-load of a production system. Watch this video to see how Vortex™ automatically balances an initially unbalanced production system. Vortex™'s auto-line balancing smooths production output and maximizes capacity.

  • Cascading Work Order Priority Support

    Vortex™ supports multiple prioritization methods, such as Critical Ratio, Numerical, FIFO, and others. In addition, it allows these methods to be cascaded, such that the organization can set its Primary, Secondary, Tertiary, etc., prioritization system preference. Thereby, when identifying the highest-priority Work Order, if there is a “tie” with the Primary method, Vortex™ will go to the Secondary method, Tertiary method, and so on down the line until the tie is broken. Having multiple prioritization methods allow a company to choose what is best for its business processes.

  • Optimize Batch-Tool Running Capacity

    Some tools in a production process have an optimum load for highest efficiency. Vortex™ identifies these load requirements and will batch work to optimize the load. This feature maximizes throughput in those cases where batching is required.

  • Optimize Continuous Load Running

    Some tools in a production process have significant set-up times and it is best to optimize the efficiency of the tool by running Work Orders with similar set-ups simultaneously. Vortex™ identifies those Work Orders allowing them to be batched for optimum efficiency. This exclusive Vortex™ feature helps minimize set-up times and increases machine utilization.

  • Maximum Completion Time

    Certain operations within a production process may be required to be performed within a certain time-frame after a prior process. Vortex™ identifies these processes and notifies production personnel of the remaining time within which an operation must be completed, resulting in reduced scrap and re-work in the production process.

  • Status and Performance Reporting

    Vortex™ has a multitude of built-in reports that come out-of-the box, including On-Time-Delivery (Actual and Projected) based on the original and current due dates, Inventory by workflow stage and by Work Center, Work Center performance to pre-defined production goals, Projected delivery date by Work Order, and many others. Management may now make performance more visible to all teams members.

  • Rework Handling

    Vortex™ handles rework and lot-splits in accordance with the company’s business policy, making required lot-splits a seamless extension of the enterprise business practices. Lot-splitting and even "bonusing" is a necessary function in many operations and this business process is accommodated by Vortex™.

  • Machine Learning and IoT Enabled

    The patented methodology developed by the Equation1 team depends initially on the accuracy of an organization’s time standards as the basis for its accuracy of delivery times. But to become even more accurate Vortex™ is coupled to an AI platform to correlate performance differences to conditions of the work product, in the production environment, and the tool sets. This allows Vortex™ to learn and improve its performance over time and becomes a key element of the Smart Factory.

  • Encrypted Communications Security

    Vortex™ uses HTTPS for all communication between client and server. HTTPS is HTTP sent over an SSL encrypted connection. SSL-based encryption technology SSL (Secure Sockets Layer) is the standard security technology for establishing an encrypted link between a web server and a browser. This link ensures that all data passed between the web server and browsers remain private, secure, and integral.

  • Active Directory Integration for Access Control

    Advanced role-based access control with integrated Active Directory based access management capability offers a very robust and secure solution for hierarchical feature management. Access to Vortex™ features is configurable and are available only to those users with the authority to use them.

  • Designed for Mobile Devices

    The Angular Javascript platform was used to develop the client-side user interface for the Vortex™ platform. This framework assures lightning-fast, secure, data delivery and mobile responsiveness across all platforms. The factory can now be run from a tablet or mobile phone!

How Does Vortex™ Work?

1. Focus

 

Focus on a given Work Center (WC) and calculate the amount of time until it will need more work than is currently authorized (Need Time).



2. Identify

 

Identify the highest priority, unauthorized, Work Order (WO) in all Upstream-Adjacent (UA) Work Centers.



3. Calculate

 

Calculate the amount of time the said WO will take to reach the focal Work Center (Arrival Time).



4. Authorize

 

Authorize the WO if, and ONLY if, Arrival Time is greater than or equal to the Need Time using the patented Vortex algorithm.



5. Repeat & Learn

 

Flow times are based on time standards that are not aware of the real-time manufacturing conditions. Industry 4.0 machine learning will improve the time computations.



How Does Vortex™ Work?

1. Focus

 

Focus on a given Work Center (WC) and calculate the amount of time until it will need more work than is currently authorized (Need Time).



2. Identify

 

Identify the highest priority, unauthorized, Work Order (WO) in all Upstream-Adjacent (UA) Work Centers.



3. Calculate

 

Calculate the amount of time the said WO will take to reach the focal Work Center (Arrival Time).



4. Authorize

 

Authorize the WO if, and ONLY if, Arrival Time is greater than or equal to the Need Time using the patented Vortex algorithm.



5. Repeat & Learn

 

Flow times are based on time standards that are not aware of the real-time manufacturing conditions. Industry 4.0 machine learning will improve the time computations.

Built on a Secure and Mobile Foundation

Built on the latest .Net Core / Angular frameworks
Cloud or on-premise installations
Database and platform agnostic
Follows industry guidelines for interoperability
Lightweight UI for access from any web-enabled device
Angular technologies create an interactive and user-friendly experience
Schedule a Live Demo to See our Platform in Action

What's next?
 

  • Discuss basic requirements +
    A member of our sales team will reach out to you by phone to discuss your basic requirements.
  • Call with product specialist +
    Next, we'll arrange a call between you and one of our digital experience specialists to dig into your needs and give you a personalized overview of our software.
  • In-depth technical demo +
    Then, we'll set up an in-depth technical demo to showcase how our full solution will benefit your business.
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