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Rapid Deployment

What is Acumence?

Acumence by Flexware is an enterprise industrial intelligence platform that provides real-time production reporting. This line monitoring software is intended for high-speed, high-volume processes such as aluminum beverage packaging. It is used in 46 factories in 22 countries and can be swiftly deployed across numerous sites with minimal support.

If you are struggling with any of the following situations, Acumence can help you:

  • Making data-driven decisions is difficult due to a lack of consistent information
  • Monitoring plant and overall performance to aid in continuous improvement
  • Accessing reliable real-time data in a single location

Rapid Deployment

Efficiency-focused industrial software for high-speed operations

By using Acumence, manufacturers can achieve repeatable operational excellence in the plant and across the organization. Because of its quick and easy integration with other enterprise systems, it is ideal for high-volume operations. Multiple sites can be integrated and managed from a central place with minimal support. The average deployment time from installation to production is 8-12 weeks.

For Operators & Supervisors

Quickly Check the Status of Your Machines With a Single Click

Streamlined dashboards for tracking machine performance

Make quick, educated decisions based on up-to-date, accurate data, whether it’s descriptive metrics, diagnostics, or predictive and prescriptive analytics. By merging machine data with human operations data, you may gain insight into OEE and manage issues before they negatively influence the bottom line.

Line Monitoring Just Got Easier

Track and receive alerts on real-time data 24/7 from a centralized location

The Acumence Server is at the heart of Acumence. Every second, it monitors over 500,000 process variables and provides them as actionable data to help drive efficiency. To record and manage high-resolution machines and data, Acumence connects with various systems, including PLCs, vision systems, databases, and ToolCONTROL. The server provides context for real-time analytics and access to all plant data, including hourly and shift-based aggregates.

Production counts
Process variable values

“We collaborate closely with manufacturers, OEMs, and other industry experts to fully understand their requirements and provide unrivaled support. Our consultants have years of experience deploying Acumence quickly to help our customers increase productivity, which has a direct impact on turnover, costs, and profit.” Jason Toschlog, VP of Products at Acumence.

Stay Connected & Informed with Instant Reporting

By providing real-time production and downtime metrics, Acumence connects management and plant personnel with their assets. Users can then easily identify bottlenecks and sources of lost productivity, resulting in increased profits and driving continuous improvement initiatives within a plant and even across an enterprise.

Manufacturers can better allocate resources and improve plant performance with instant graphical summaries like shift overviews and downtime Pareto charts. Many reports make it possible to delve down into which equipment and machines are incurring the most downtime and scrap. As a result, operators may rapidly identify the source of an issue and resolve it before it affects the bottom line.

Acumence FAQs

What are the main components of Acumence?

Acumence is made of two essential parts: the Acumence Server and the Acumence Client.

Acumence Diagram

What manufacturing information can Acumence provide me?
Plant Information
  • Acumence connects management and plant personnel with their assets by delivering real-time production and downtime metrics.
  • Users can then easily identify bottlenecks and sources of lost productivity, leading to increased throughput and profits.
  • Acumence provides insight into plant operations that drives continuous improvement initiatives within a plant, and even across an enterprise.
Plant Performance
  • Acumence keeps track of factory production details and machine status in production lines.
  • Production information is tracked for each machine in the plant, and for each plant in the enterprise.
  • Analysis tools enable management to compare crews, shifts, lines, and even factories.
  • This allows management to identify best practices and opportunities for improvement through training.
Real-time Alerts
  • Acumence is architected with a memory-resident data structure that ensures high speed for aggregation, processing, and presentation of results.
  • It also can capture, store, and display information immediately.
  • The animated and color-coded client screens keep everyone informed on up-to-the-second operations, drastically minimizing downtime and loss.
Historical Reports
  • The Acumence Database, a component of the Acumence Server, keeps a long-term record of all monitored activity.
  • A comprehensive set of reports, analysis, and trending tools are available when it is necessary to look at a machine or plant’s performance in more detail or over a longer period.
  • Users can drill down into reports to find additional details.
Manufacturing Solutions
  • Acumence is built on a platform fit for nearly any discrete manufacturing process.
  • Specific configurations for beverage can manufacturing are available that will speed implementation and ROI.
What can Acumence connect to?

Acumence interfaces seamlessly with a wide range of software and OEMs. It can connect with all PLCs, including ControlLogix and Siemens, in common machine types using standard OPC servers. Acumence can also interface with all common inspection camera systems, such as Applied Vision and Pressco, via vendor OPC servers. Standard database connectors allow it to communicate with a wide range of third-party business applications, including ERP, maintenance, and quality management systems.

How does Acumence assist aluminum beverage can manufacturers?

In the high-speed operations of two-piece can manufacturing, bottleneck analysis and preventative maintenance can have a substantial impact on overall output and production efficiency. Acumence enables manufacturers to quickly identify which machines are causing problems farther down the line, allowing them to improve line flow and increase efficiency.

Taking action to perform maintenance and change tools before major problems arise is critical to reducing scrap and minimizing downtime.

The following graph shows how Acumence helps aluminum beverage can manufacturers enhance performance on both the front-end and back-end:

Front-End CapabilitiesBack-End Capabilities
Cupper

  • Coil yield analysis
  • Billed vs. actual footage
  • Coil gauge reduction

Bodymaker

  • Cycles per tool pack reporting
  • Short can tracking
  • Coil quality monitoring

Washer

  • Cleaning parameters
  • pH, zone temperatures

 

Decorator

  • Faster changeovers
  • Trips/mandrel tracking
  • Throughput optimization

Pin Oven & IBO

  • Natural gas usage reduction
  • Temperature monitoring

Spray Gun

  • Lacquer usage reduction

Necker

  • Transfer jam/station tracking

Palletizer

  • Pallets into the warehouse system
  • Pattern tracking
How does Acumence monitor bodymaker and trimmer performance?

Acumence helps manufacturers to quickly identify specific machines and tooling that are responsible for higher than average scrap or downtime.  This allows operators to quickly identify where an issue is and take action to fix the root cause of the problem. As a result, the bodymakers and trimmers are more efficient, there is less scrap, and the rest of the production process runs more smoothly.

ToolCONTROL by Integrated Packaging Solutions (or IPS) is also a plugin that connects easily to Acumence. ToolCONTROL is a tool monitoring and inventory management system tailored to the can manufacturing industry. ToolCONTROL is a user-friendly framework for controlling inventory and monitoring tools. It will ensure Bodymakers have access to the right tools at the right time by knowing the tools are in stock and what inventory gaps need to be filled.

What factory environments and plant personnel benefit the most from using Acumence?

Acumence is specifically designed to handle the following types of manufacturing environments:

  • Real-time
  • High-volume
  • High-performance
  • High-speed

Acumence provides plant managers, operators, supervisors, and executives with up-to-the-second information on machine and production performance.

What does the implementation process look like?

The average deployment of Acumence takes 8-12 weeks from installation to configuration. We did, however, deploy Acumence in 5-8 weeks in a few cases. It is all dependent on a variety of factors, including how much data is already being collected, the size of the installation, and the availability of local resources.

Rapid Implementation Timeline
2 WeeksInitial installation and modeling
2 – 4 WeeksConnectivity to machines that are integration-ready
Situation DependentConnectivity to machines that need controls, sensors, and networking
Deployment Methodology

The following stages are necessary for a successful rapid implementation. Each stage has steps that the Acumence team, a systems integrator, and the customer must complete.

  1. Plant PLC Preparation
  2. Configuration & Dashboard
  3. System Install
  4. Administrator & User Training
  5. Post Install Support & Updates
What is included in the licensing?

A license for Acumence includes unlimited machine integration and unlimited users. The pricing is based on per plant. When purchasing several plant licenses in a package, customers can receive a discount.

Customers can purchase annual software support and maintenance packages. This plan includes access to 24/7 product support, software updates, and online documentation through the Client Portal. For all levels of maintenance service, Acumence will provide at least the following minimum response times for service:

ServiceSupport WindowResponse Time
Information RequestBusiness Day2nd Business Day
Non-Critical ProblemBusiness DayNext Business Day
Critical Problem24/7/3654 Hours

Still interested about how Acumence can help your operations?

Learn more about the software in this video.

Ready to get actionable insights into your manufacturing operations?

Let’s talk.