IQS Group
How IQS Group improved traceability and saved 100 minutes of daily paperwork thanks to MES Softli
“In addition to perfect traceability of input materials, MES SoftLi has also relieved us of a significant administrative burden. Each operator saves at least 5 minutes during an 8-hour shift. With ten workstations and a two-shift operation, that’s 100 minutes a day. The system is truly 21st-century software – fast, flexible, and intuitively operated.”
Lenka Silberhornová
Business Intelligence Manager, IQS Group
About the client
The companies of the IQS Group supply top-quality products and technologies to the international market, covering areas from anti-counterfeiting solutions and nanostructured optics to 3D printing and medical applications.
IQ Structures specializes in cutting-edge solutions for anti-counterfeiting. Blending design with proprietary technology, it delivers advanced optical security features for banknotes, IDs, and other secured documents.
IQS NANOPTIQS pioneers ultra-thin and miniaturized printed optics with exceptional properties. Its lighting solutions serve a wide array of industries, including LED lighting, gallery installations and automotive applications.
IQS nano focuses on developing lithographic and 3D nano-printing technologies and creating their applications in anti-counterfeiting, nano-optics and bioengineering.
IQS Group’s main clients include central banks, national security printers and state agencies responsible for issuing ID cards, passports and secure documents.
Challenges before implementation: from pen and paper to a long-term unsustainable system
At IQS Group, production runs on specialized machines with long cycles. To transfer miniature patterns into physical materials, the company uses multiple technologies, each requiring specific equipment. “It all starts with an idea – the graphic design of a security feature for a banknote or ID card. The challenge is to combine top-level security with strong visual appeal,” Silberhornová explains.
Given the strict certifications involved in handling security-sensitive materials, IQS Group must meet high traceability standards. Every material input must be recorded, and strict procedures must be followed for the disposal of intermediate products.
“We transitioned from pen and paper to Excel over time,” Silberhornová recalls, “but even Excel became overwhelming for the operators. We needed a solution that would reduce their paperwork and still ensure traceability across every production step.”
As production increased and the company moved to a two-shift operation, the situation became critical. “We simply couldn’t keep up using only Excel, pen and paper,” says Silberhornová. “It wasn’t sustainable, and the quality would have dropped below the levels required by our certifications.”
Key issues, that had to be resolved:
High administrative burden for operators
Need for automated production tracking
Elimination of human error in waste recording
Difficulties in waste tracking due to material expansion
“Production material expands, so if we tracked waste by linear meters, the product’s length differed at every stage of production. Therefore, we began giving products serial numbers and adjusted how we track production,” says Silberhornová.
Why was MES SoftLi selected?
IQS Group reviewed multiple systems, including MES and ERP solutions with manufacturing modules.
“Our production director was convinced after a reference visit to another SoftLi customer – Partner in Pet Food,” says Silberhornová. “We were looking for a system that would adapt to us, not the other way around. SoftLi stood out with its flexibility – it was able to adjust to our specific needs. Compared to other MES systems, it’s modern, fresh and highly adaptable.”
Implementation: a demanding process with unexpected challenges
Getting the system up and running was unexpectedly quick. The real test, however, came shortly after.
“At first, it seemed like it was going to be a walk in the park. We had MES SoftLi installed on our server shortly after we provided access,” recalls Silberhornová. “But then came the real challenges – especially when it came to deploying machine monitoring.
Technical challenges during implementation:
01 Installing sensors on machines without interrupting operations
02 Customising the system for constantly changing orders
“Our production process is constantly changing – different materials, different workflows, different dimensions. We’re not producing a standard item in multiple variations. Each order is unique, and it always starts with extensive testing,” explains Silberhornová.
03 Implementing miniature DMX code reading
“We had to find a technology capable of reading DMX codes as small as 8×8 millimetres – sometimes even smaller. Many of them are printed on transparent materials, so lighting conditions had to be factored in as well.”
“In the end, we replaced the original solution with a Keyence camera, which offers higher resolution and can read such small codes.”
Four Key Benefits of MES SoftLi for IQS Group
1 Perfect traceability of input materials
“What helped us the most is the Trace module – it gave us full control over traceability of input materials. For every job, we produce a master matrix that serves as the basis for replicating our structures. We must always know exactly which matrix was used for each product.”
2 Accurate waste tracking
“MES SoftLi helped us keep 100% accurate records of all production waste. “
3 Secure information distribution
“We needed a more secure and efficient way to distribute information at the workplace – and the Forms module made that possible. We now deliver updates directly to machine terminals, meeting all our safety requirements. We are in control over both production and information flow. “
4 Clear and Fast Reporting
“I really appreciate the reporting MES SoftLi offers. Thanks to the Reports module, we have an instant overview of production and can respond efficiently to any deviations,“ says Silberhornová.
Clear communication helped overcome the initial resistance of employees.
Introducing the new system caused some fear among employees. „At first, operators were really afraid it would be a tool to monitor their work and that every downtime might lead to wage deductions,“ Silberhornová recalls the initial reactions. „That’s why we had to communicate a lot with them and explain that the software is meant to help them.“
At IQS Group, quality is key, not volume. „Given that we work at the nanoscale, precise machine calibration is vital, as any mistake forces us to discard the product. And that is far more expensive than a short downtime.“
Results of MES SoftLi Implementation
MES SoftLi helped IQS Group with:
Saving time: The system saves each operator at least 5 minutes of paperwork during an 8-hour shift, which means 50 minutes per shift across ten workstations. With a two-shift operation, this totals 100 minutes saved daily.
Increased traceability: Ensuring 100% traceability of materials used in production along with precise waste records.
Improved corporate presentation: “We show MES SoftLi often during customer visits in production. The reactions are very positive and it leaves a favorable impression,” adds Silberhornová.
Besides the practical benefits, Silberhornová also values the support from the supplier: “The initial enthusiasm from everyone at SoftLi was crucial for us, as the beginnings were quite challenging and SoftLi had to go far beyond their usual responsibilities. Without that initial commitment, it wouldn’t have gone well.”
