Gilard Application Programmers - OSM Features.pdf

Because leaders know better.
Make your organisation Industry 4.0 compliant.
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Operating System for Manufacturing - a pre-requisite for Industry 4.0. GAP LLP PRESENTATION
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Because leaders know better. 2
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Industry 1.0
Industry 2.0
Industry 3.0
Industry 4.0
1784 1870 1969 Now
Industrial Revolutions
Mechanisation
of Production
Electrification
drove mass
Production
Electronics &
IT drove
Automation
Cyber Physical
Systems
Power loom
Assembly Line
PLC
Degree of
Complexity
Introduction of Mechanical
Production Machines
powered by Water, Steam,
Animals or Humans.
Introducing mass
production lines
powered by Electrical
Energy
Added use of Electronics
and IT. Further
progression in
autonomous production
Based on cyber physical
systems. Usage of IOTs
and Cloud Computing.
Industry 4.0 - a history
The 3 previous industrial revolutions are considered as the
Mechanisation of Production, Mass Production and Automation respectively.

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What is Industry 4.0
McKinsey defines Industry 4.0 as digitisation of the manufacturing
sector, with embedded sensors in virtually all product components
and manufacturing equipment, ubiquitous cyber physical systems,
and analysis of all relevant data.

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Virtual Twin with I-4.0
Imagine a Virtual Twin for your manufacturing unit.
Physical world activity displayed on the computer screen in real time.

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Company Overview
Gilard Application Programmers LLP (Limited Liability Partnership) is the sister
concern of Gilard Electronics Pvt. Ltd. which is a 60 year old brand (established
since 1961) and is a well known and reputed name in the automotive industry.
Gilard Application Programmers LLP is one of the frontier names in India who
provide Industry 4.0 solutions to the Manufacturing Sector. The flagship product of
the company is a Business Management Software called OSMTM (Operating System
for Manufacturing) which is the foundation on which Industry 4.0 stands.

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Company Statement
Vision: To make OSMTM the worldwide standard for the Digital Management of the
Manufacturing Industry.
Mission: To offer hardware and software solutions and help the industry to
implement a Digital Management* solution that helps them to excel and work
towards achieving their Vision.
*Digital Management means that one can manage everything digitally. This
includes your resources - Man, Machine, Money, Material and Methods (Processes
and Controls) digitally so that everything is available to you in the digital arena.

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OSM - AN INDUSTRY 4.0 SOLUTION
The company is working under the vision of Mr. Sanjiv Singh Sethi
(CEO) who is also the current Managing Director of Gilard Electronics
Pvt. Ltd. He has 42 years of manufacturing experience and has 34
years of experience in software development. He is one of the
leading specialists on the subject of Industry 4.0 who has been
invited to give talks on the subject on various platforms. He has also
written extensively on the subject and has successfully implemented
INDUSTRY 4.0 at the Mohali plant of Gilard Electronics Pvt. Ltd.

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OSM Software
The GAP OSMTM software is the flagship product of Gilard Application Programmers
LLP. This software provides the foundation for Industry 4.0 and Smart
Manufacturing by digitising all the manufacturing as well as all the business
processes in an organisation.

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OSM Solutions
SOLUTIONS IN GAP OSM
Besides the above 20 modules, the software also has the following 3 portals :
1 Legal Entity - GAP OSM Software
Asset Management Dashboard (MIS) Document Control
e-CAPA (Corrective and
Preventive Actions)
EHS (Environment, Health &
Safety)
Finance
HRD (Human Resource
Development)
Manufacturing
NBD (New Business
Development)
NPD (New Product
Development)
Payroll
PLM (Product Life
Management
(PCMD) Process Control
Monitoring Device
Purchase Sales Stores
Tool Room
TPM (Total Productive
Maintenance)
QA (Quality Assurance) Visitors

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OSM - Ideal for Manufacturing
Domain knowledge of
manufacturing from top Quality
companies like Maruti, Toyota,
Bosch, Honda & Mitsubishi.
OSM customers have won
ZED Diamond Rating
&
ACMA’s Gold Award for Digitisation
Software provides a platform
for IoTs, M-to-M interaction.
GAP OSM - “Developed by the
Manufacturing Industry for the
Manufacturing Industry”
Integration of Design, Development,
Manufacturing, Supply Chain, Quality with
business processes.
Simple to learn, understand and
operate.

How Awesome is OSM?
Modules of OSM
Create a Twin Virtual Factory with OSMTM to be always informed.
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OSM Key Functions
Business Lead Management (CRM, CLM) APQP/PPAP based Project handling Vendor Selection Order Booking
Risk and Relevance Study Product Design - Function Study, BOM,
QFD, DFMEA
Product Approval Quotations / Proforma Invoices
Cost and Profitability Study
Process Design - Make or Buy,
Drawings, Tool Designs, Outsourcing
Purchase Order generation via MRP Configurable Invoicing / GST compliant
Capacity and Capability Study
Process Development - Tooling, PFC,
PFMEA, Control Plans
Supply Monitoring Billing linked with Inventory
Project Initiation Product and Process Validation Linked with Purchase Vouchers Schedule Monitoring
Techno-Commercial Offer generation Transfer to Production Vendor Payments Credit Control / Payment Follow up
Annual Growth Plan and Review Continuous Monitoring and Improvement Vendor Performance Rating Sales Reports
NBD Function
(New Business
Development)
NPD Function
(New Product
Development)
Purchase
Function
Sales
Function

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OSM Key Functions
Asset Master Cash, Journal & Purchase Vouchers Sales Reports Register In / Out of Visitors
Asset Register GST Accounting Financial Reports Maintain Visitor Profile
Asset Identification and Audit Trial Balance and Bank Reconciliation Order vs Delivery Reports
Real Time monitoring of all visitors
within the organisation
Asset History
Employees Tour and Travel Bills, Mobile
Bills
Quality Reports Control of OT by employees
Depreciation calculation Balance Sheet, Profit & Loss, Ledgers Expense Reports
Visitor Safety during emergency
evacuation
MIS Reports Production Reports
Cost Accounting (PQA) Compliance Reports
Asset
Management
Function
Finance &
Accounts
Function
Advanced
Analytical
Dashboard
Visitors
Function

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OSM Key Functions
Incoming, In-process and Final
Inspection
Production Data Control for optimisation Corrective and Preventive Action Machine Master List
Review and disposal of Non-conforming
material
Product Cost Improvement Customer Complaint and resolution
History
Autonomous Maintenance Activity List
Corrective and Preventive Action, Item
wise History
Assembly Line Layout & Balancing
Audit Non-conformities and resolution
history
Machine Preventive Maintenance
Schedule
Rejection Monitoring in ppm Document Review and Control
Internal Quality Failures and resolution
history
Spare Parts Inventory
Dynamic Inspection Plan Product & Process Audit
Machine Breakdown and resolution
history
Breakdown Maintenance handling
Multi-level data collection of Poor
Quality
Control the machine, tool, cycle time,
machine control parameters.
MTTR, MTBF, MPBF
Calibration and MSA, Auto Process
Capability Studies
Process Capability Studies (Cp/Cpk) Control on Machine Sponsor Visits
QA (Quality
Assurance
Function)
PLM (Product
Life
Management)
e-CAPA
Function
TPM (Total
Productive
Maintenance)

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OSM Key Functions
Monthly Production Planning Tool Master List Multi-level inventory control Platform for IIoT
Daily Production Monitoring Breakdown History of all Tools FIFO implementation Bridge to Industry 4.0
Monitoring of Machine and Operator
Efficiency
Tool Breakdown Maintenance Handling Tracking of shelf life items Compatible with Digital & Analog Sensor
Internal Flow of Material Tool MTTR Traceability of material Real Time Data from Machines
Production Reports Tool MPBF Control on consumables Live Monitoring of Production
Monitoring of Resources - Electricity,
RM, HR expenses, Consumables
Job Card for all Tool Makers Material Indent System MIS Production Reports
Control and accountability of Scrap
generated
Quality Approvals after Repair Control on ITR
Manufacturing
Function
Tool Room
Function
Stores
Function
PCMD
Function

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OSM Key Functions
Employee Data
From Biometric Input to creation of
Attendance Register
Legal Compliance Monitor
Availability of Controlled Documents to
different departments
Recruitment & Probation Monthly Payroll Aspect - Impact Study Access to previous revisions
Participative Management All related reports like ESI and PF
HIRA (Hazard Identification and Risk
Assessment) Study
Control of Policies, Manuals,
Procedures, WIs, Plans & Formats
Employee Satisfaction Survey
Annual Reports, Bonus, EL, CL and
Annual appraisal
Availability of MSDS
Skill Development & Monitoring Leave Management System Emergency Plans
Behavioural Competency Overtime Control System
PMS
HRD (Human
Resource Dev.)
Function
Payroll
Function
EHS (Environment
Health & Safety)
Function
Document
Control
Function

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OSM Portal Functions
Accessible for all employees through any device 24 X 7 access to the portal for any information 24 X 7 access to the portal for any information
Access to Company Rules & Regulations Place orders online through the portal View pending schedules
Review, approve and apply Leaves Access all due payments Generate ASN before dispatch
Enables Transparency by showing payslip to employee Track pending orders and dispatches View and reconcile ledger
Provides platform for Suggestions or Grievances Track New Product Development Activities View supplier report and rating
Register for Trainings and view training content Register customer complaint to senior management Access Supplier Quality Manual
View PMS (if connected to full OSM solution) Submit CAPAs
Employee Portal Customer Portal Supplier Portal

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OSMTM - DD Production Module
OSM Digital Display Production Module is implemented on the Digital Display Devices on every machine.
1 Legal Entity - GAP OSM Digital Display Production Module Software
Autonomous Maintenance Live production tracker Machine History Patrol Inspection
Product Drawing Process Parameter Sheet Production Statistics Quality Alerts
Raw Material Usage Details Skill based Machine Sign In Tool History Troubleshooting
Note:
• A single OSMTM - DD Production module license gives access to the above mentioned functions.

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OSMTM - Employee Portal
OSMTM Employee Portal Software Licenses are issued for all employees - permanent or contractual.
1 Legal Entity - GAP OSMTM Employee Portal Software
Attendance Register Company Rules & Regulations Earned & Casual Leave Ledger Employee Account Ledger
Leaves Application & Review List of Annual Holidays Organisation Chart Register a grievance
Training Registration & Record Suggestion Scheme View Payslip View PMS
Note:
• A single OSMTM - Employee Portal software license gives access to the above mentioned functions for all
employees - permanent or contractual - through the use of Public Kiosks.

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OSMTM - Customer Portal
OSMTM Customer Portal Software Licenses are issued for all customers.
1 Legal Entity - GAP OSMTM Customer Portal Software
Compare orders vs dispatch Place an order / schedule Register a complaint Track Development Activities
View Account Ledger View Pending orders View Pending Payments View Recent Despatches
Note:
• A single OSMTM - Customer Portal software license gives access to the above mentioned functions for all
customers. This portal is linked to the OSMTM software.

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OSMTM - Supplier Portal
OSMTM Supplier Portal Software Licenses are issued for all suppliers.
1 Legal Entity - GAP OSMTM Supplier Portal Software
Acknowledge PO / Schedule Audit report - Quality & System Register complaint/suggestion Track Development Activities
Upload Sale / Dispatch Info View Account Ledger View Pending Schedules View Recent Receipts
Note:
• A single OSMTM - Supplier Portal software license gives access to the above mentioned functions for all
suppliers. This portal is linked to the OSMTM software.

Features of OSM
Use OSMTM software, IIoTs, Digital Displays and Hardware to
create a Smart Manufacturing environment.
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How Awesome is OSM?

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MIS Reports
Dashboard
The Dashboard offers
the view of all the
parameters that would
be of interest to the
senior management with
just the click of a button.
Dashboard for Management

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Sales Analysis Reports
Sale Trend Charts
Availability of Trend
charts for Sales -
Customer wise, product
wise, Area wise, Segment
wise or even Relationship
manager wise,
Trend Chart for Sale Analysis

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Plan your Production
Production Planning
Easy to make monthly
production planning
using Gantt Charts,
taking orders received
and current inventory
levels as input.
Production Planning

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Production Analysis Reports
Production Trend Chart
Availability of Trend
charts for Production -
Machine wise, Operator
wise, item wise can be
analysed to improve
productivity.
Productivity Trend

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Develop New Products using best practices
New Product Development
Development of New Product
is done through a APQP /
PPAP based system which
include sub-processes like
Function Study, QFD, FMEA,
PFC, Control Plans, DVP, etc.
New Product Development

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Document Creation, Control & Accessibility
Control Plans
Availability of control
plans to all production
and quality team
members for streamlining
production work
instructions and quality
requirements.
Quality Control Plans

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Process Control Monitoring Device
Monitor your Manufacturing Processes
PCMD - v1.0 can be used to connect 12
digital ports via LAN for monitoring
machine production in real time.
Machine Sensor PCMD
Cloud
Server
Digital Display on
Machines
Auto SMS Texts
Management
Reporting
DATA COLLECTION
REPORTING

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PCMD - v2.0 can be used to connect 12
configurable ports via LAN or wi-fi for
monitoring analog / digital input. It can be
used with both potential and non-potential
sensors.
Process Control Monitoring Device

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All machines are installed with sensors
which capture data which is then sent to
the PCMD and displayed on these digital
display devices.
Digital Display Devices on Machines
Machine operator with Digital Display

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Digital Displays on Machines compatible with PCMD
Machine Interactive Screen
Production operators can
view production details like
current production and
targets on the screen.

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Real Time Production Data from Sensors on Machines
IIoTs and Big Data
The Data is auto
collected from machines
and sent to the server
where it is converted
into information and
analytical reports.
Auto Data Collection & Auto Analysis

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Online Inspection
Inspection can be performed on
the digital platform and captured
and shared in real time with the
management.
Inspection Sheet

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Machine Parameters
For critical processes,
continuous monitoring of
machine parameters can be
done on the software.
Machine Parameters
140
148
155
163
170
Nozzle Temp Temp Zone 1 Temp Zone 2 Temp Zone 3

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Live Production Tracking
Real time production tracking
can be done by anyone sitting
anywhere in the world.
Live Production Tracking

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Autonomous Maintenance Checkpoints
Production operators can view
checkpoints of autonomous maintenance
on the screen in local language.
Autonomous Maintenance Checkpoints
Self learn tutorial videos

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Automated M-2-M Escalation
Automated Text Message Notifications
The software sends automated text
messages on phones for notification on
any abnormality.

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Online Attendance Biometric Machine
Monitor Employee Movement
Biometric - v1.1 can be used for
attendance system and monitoring
employee movement in real time via LAN
or wi-fi. It can be used to authorise and
record the person performing the process.

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Monthly Salary Slips
Salary Slips
Streamlined and auto
generation of monthly
salary slips using the
biometric punch system
based on attendance,
leaves, overtime ensures
zero error in salary slips.
Biometric Punch to Payslips

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Thank You

Gilard Application Programmers - OSM Features.pdf

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