HOST COMPUTER SYSTEM. Digital production control

Transcription

1 HOST COMPUTER SYSTEM Digital production control

2 NETWORKER Efficient, cost-effective, online: digital production management powered by ARBURG. 2

3 More transparency, more flexibility, more efficiency! Our ARBURG host computer system (ALS) is a detailed planning tool for your injection moulding production that sets new standards. Process data is captured online, clearly prepared and available end to end. Direct, reliable, active. Turning big data into smart data! Start your digital transformation with ARBURG as your smart partner. 3

4 AT A GLANCE // Saving time and costs: our modular ARBURG host computer system (ALS) offers you all the features that you need for the efficient organisation and cost-effective optimisation of your injection moulding production. With experience from several hundred installed Manufacturing Execution Systems (MES), we deliver the ideal basis for your digital transformation. \\ Greater flexibility: wide range of options for integrating the entire production facility, such as I/O modules, for example. More efficiency: optimal utilisation of the available resources thanks to a central overview. 4

5 Practical management Networking of the complete production facility, including manual workstations? ALS offers you every freedom in this regard: from input terminals and I/O modules through to standardised interfaces for injection moulding machines of all manufacturers. Your system can always be flexibly extended thanks to combinable modules. Detailed planning Special injection moulding production features such as mould inserts, for example, make detailed planning excessively complex for conventional ERP, PPS and PDA control stations. With ALS, you optimise your systems based on online data, capacity utilisation, quality and delivery reliability of your production. Reliable information ALS actively informs you and keeps you up-to-date worldwide. Feedback and key figures relating to machines, orders, shifts and production quality are immediately available. Maximum transparency, wherever, whenever and however you need it: whether on the PC, in the production facility or when mobile. Simple implementation We plan and implement the suitable ALS system solution together with you. On-site guidance, as well as comprehensive training options ensure a high level of acceptance among your employees as well as amortisation of your investment in a short time. Automatic archiving Reliable documentation without complicated manual data acquisition and incorrect entries. This simplifies audits and certifications considerably, leaving you more time for organisation and optimisation of your production ALS also assists you here in a targeted manner. Greater transparency: precise information allows you to make analyses and decisions at all times and anywhere in the world. 5

6 GET ON BOARD // The ARBURG host computer system (ALS) is the central tool for efficient organisation of your injection moulding production and therefore an important step towards the smart factory. In order to help you get started, we have put together the ALS package. This ensures transparency right from the start and allows you to achieve significant time and cost savings. The modular configuration can be extended at any time, enabling you to react quickly to new requirements. \\ ALS package overview Use this pre-configured module selection to make your daily work even more efficient. Production organisation: optimise with online information. Production networking:with an open structure. Production data: make available in real time and across locations. Production documentation: clear and available per click at any time. Setting data: convenient and secure archiving. FLEXIBLE MODULAR KIT for the configuration and extension of your host computer system 6

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8 ONE TOOL FOR EVERYTHING! Base 609/01 Material Staging Interface 610/24 ERP- Interface 610/05 Remote 610/06 Batch 610/23 MES- Interface 610/18 Orders 610/03 Mobile Production 610/20 Documents 610/12 Resource conflict 610/17 Programs 610/02 Datawarehouse 610/14 Events archive 610/19 Production variants 610/16 Mobile Monitoring 610/21 Reports 610/01 Programs Plus 610/09 Clients 613/01, 05 OPC-UA Connector 612/22 Progression 610/08 Quality 610/04 Mobile Maintenance 610/27 Set-up log 610/10 Maintenance 610/11 Terminal 613/20, 21 Device Connector 612/21 Production log 610/15 Maintenance verification 610/26 Info 610/22 ALLROUNDER Interfaces 611/11, 14 Machine Interfaces 612/xx Energy Visualisation 610/25 Energy Visualisation Interface 611/15 Groupware 610/13 Web-I/0 alarms 611/09 I/0 Modules 611/0x Web-I/0 condition 611/08 Functional module Required module Interface module Dependent module 8

9 Information centre Base: acquire data for production overview and manage moulds Remote: remote maintenance via Internet Mobile production: mobile MDA or PDA terminal Mobile monitoring: production information on mobile devices Information: individual info screens Mobile maintenance: maintenance terminal for mobile devices I/O modules: connection of any machines/workstations via signals Web I/O condition: measuring ambient conditions Web I/O alarms: output devices for central alarm signalling ALLROUNDER interfaces: connectors for ALLROUNDERs Energy visualisation interface:connection licenses for energy meters Machine interfaces: connectors for injection moulding machines and protocols of various manufacturers Device connector:system data acquisition via network OPC UA connector: data acquisition via OPC UA Clients: access ALS server from PC workstations Terminal: enter data manually Production management Orders: plan and monitor orders ERP interface:exchange data with PPC/ERP system Maintenance: manage, monitor and document maintenance orders Groupware: automatic notification of events and creation of cyclical reports Production variants: plan alternative moulds and take account of machine performance Resource conflict: monitor moulds for double assignment MES interface: exchange data with production management systems Batch: batch change documentation Material staging interface: exchange data with material provisioning systems Maintenance verification: verify maintenance tasks Quality assurance Programs: manage programs and transfer them to the machine Quality: statistical process control (SPC) and interface to quality assurance systems Programs plus: create parameter lists and comparisons, full text search Documentation Reports: analyse order, item, mould and machine-related evaluation and export data Progression: create event log Set-up log: daily back-up of set-up log Documents: link documents with orders, programs, maintenance and much more Data warehouse: save states and events in database Production log: permanently archive process parameters Events archive: archive event data in database Energy visualisation: capture and document energy data Modules in ALS package 9

10 Standardised: Ethernet network, e.g. on basis of the OPC UA communication platform. Direct: feedback via touch terminal, e.g. provision of moulds. POWERFUL INFORMATION CENTRE // Quickly and flexibly respond to constantly changing requirements? No problem with our powerful ARBURG host computer system (ALS). It enables close IT networking and online data exchange. Across all your production facilities and locations - throughout the world. But also with your production planning and control system (PPC) or enterprise resource planning system (ERP). For a direct flow of information from the machine to material planning, Highlights purchasing and sales. This is digital transformation at its best! \\ Tailored to injection moulding Completely connected production production The latest information at your fingertips including on mobile equipment Evaluations per click 10

11 NETWORKED INTERACTION on the basis of an industrial Ethernet network MANAGEMENT Vertical integration PPC/ERP PRODUCTION MANAGEMENT PRODUCTION ALS Ethernet Ethernet Horizontal integration 11

12 1,250 HOURS OF WORKING TIME SAVED PER YEAR by dispensing with manual data entry in the case of 20 machines Central and comprehensive: integrate the entire machine fleet and acquire production data online. 12

13 A RELIABLE DATA BASIS ENSURES EFFICIENT PRODUCTION. Central acquisition The basis for cost-effective production: central management of master data with online acquisition of order progress, machine statuses, process parameters and alarm messages. This enables you to plan down to the minute at all times. The combination of machine and production data acquisition (MDA and PDA) allows you make target/actual comparisons, to optimise sequences and reduce set-up times. Horizontal integration Vertical integration By means ofseamless integration with your higher-level PPC/ERP system, ALS receives order data and automatically transmits the order progress. This ensures up-to-date production data and increases the added value of your planning system. You can choose where, when, how and which information is made available to you: from the smartphone to the flatscreen. This results in fewer internal queries regarding the status of production orders. Enabling you to integrate all production systems even across several locations. Your options: input terminals for older machines and manual workstations I/O modules for simple connection of any machines and plants Standardised interfaces for all makes of injection moulding machine Our ALLROUNDERsoptimally interact with ALS, e.g. when exchanging setting data or recording fault causes. 13

14 PREVENTIVE QUALITY ASSURANCE // Your setting data is priceless. That is why we collect and archive your data secured against loss with our ARBURG host computer system (ALS). This guarantees that your production only uses the current, most recently optimised and released change statuses. Diskettes and memory cards: a thing of the past! Your product quality is constantly reproducible, complaints tend towards zero. A further advantage: you are perfectly prepared for audits and certifications. \\ Always up-to-date: central access to optimised and approved setting data. 14

15 Improve quality The recording and monitoring of actual values makes changes in the production process traceable and contributes to high product quality. Reference values and tolerance bands can be managed product-specifically. You will be warned of imminent quality deviations and can respond in time without having to interrupt production. Proof of quality Archive setting data Setting logs and corresponding screen pages of the machine control system can be archived with the setting data. This makes it much easier to find the relevant data for a specific production combination. Also easily possible: creation of parameter overviews from archived setting data or a detailed comparison of data sets. This enables you to document the settings even during a batch or a currently active order. Order-specific logging and archiving of the actual process values leads to seamless verification of production quality. Detailed long-term analyses, statistical evaluations and proof of process capability, for example according to ISO TS 16949, can be implemented. Close networking with quality assurance systems is also possible. Permanent traceability: order-specific recording, monitoring and documentation of actual process values. 15

16 Ideal for shift operation: active, instant feedback via . We are technology and system partners for IT networked production - more than 30 YEARS OF EXPERIENCE EFFICIENT PRODUCTION MANAGEMENT // Manage your available resources, save time and minimise costs. It s simple with our ARBURG host computer system (ALS). Through direct assignment of orders to machines and the creation of queues via the planning chart. With forward-looking detailed planning of machine utilisation, production dates, unit volumes, set-up and maintenance work including personnel requirements. Data exchange with planning systems such as SAP is fully automatic. All of this makes your order planning and monitoring reliable and transparent. \\ 16

17 Central management Integrative and interactive: your order planning triggers the provision of the setting data, moulds and materials required for production. The setting data is transmitted directly to the machine when production of the order commences. This makes production intelligent. Plan precisely to the minute Fully utilise capacities, minimise setup and maintenance times all this requires precise information. Include specialities such as the number of cavities, family moulds, master moulds or peripheral equipment in your detailed planning. Targeted data exchange also supports areas such as warehousing, mould construction or maintenance. Reliable delivery The current scheduling status at a glance: an active display of bottlenecks and potential delivery delays means you can provide information and act on an ad hoc basis. This helps you to ensure the timely manufacture of your products and thus a high level of customer satisfaction. Maximisation of availability You can centrally manage and document all maintenance orders for moulds, machines and peripheral equipment at one location. The continuous monitoring of deadlines and automatic reminders for pending work via text message, or info screen protect you against unscheduled machine downtimes. 17

18 Shift report - detail [ 01/13/09-01/13/09 ] Machine Total [h:mm] Auto [h:mm] Alarm [h:mm] Manual [h:mm] Offline Utilisat. [h:mm] [%] Count Count Count Count Good parts Bad parts Alarms Errors 01/13/09 S3 1200T 8:00 7:29 0:06 0:25 0:00 93, U 8:00 8:00 0:00 0:00 0:00 100, V 8:00 7:51 0:01 0:08 0:00 98, U 8:00 7:39 0:01 0:20 0:00 95, U Fuchs 8:00 7:41 0:02 0:18 0:00 96, Mould 2 sheet 275V 8:00 7:46 0:04 0:10 0:00 97, A Resin 8:00 8:00 0:00 0:00 0:00 100,00 Mould: A 8:00 8:00 0:00 0:00 0:00 100,00 Description: 973 Abdeckung A 2K Mould type: 8:00 7:42 0:02 0:17 0:00 96, Injection mould U 8:00 7:33 0:01 0:26 0:00 94,31 Version: 1016 Standard mould Status: producing 570C 8:00 8:00 0:00 0:00 0:00 100, Status planned un S 8:00 6:54 0:15 0:51 0:00 86,29 inhibited: no S 8:00 8:00 0:00 0:00 0:00 100, :00 100:34 0:32 2:55 0:00 96, Status - processing resources accounts [ 01/26/09-01/30/09 ] 170U PP [h:mm] Operating hours 126:00 Production duration (main utilisation time) 107:08 Total standstills 18:52 15% 85% Standstills acc. to prod. means accounts PS Secondary utilisation time PI Technical interruption PIO organisational interruption PIP personnel interruption PIX non-classified interruption OPN Out of production not planned OPP Out of production planned CON Conversion SU Start-up [h:mm] 0:00 2:50 7:51 0:00 4:08 0:35 0:00 3:10 0:18 0% 0% 3% 0% 2% 15% 42% General: 22% Mould group: current location: Main location: Cavities: 17% Maintenance interv vertikal PS Cycles Dimensions / weights Mould height: Opening height: Clamping dimension: Mould weight: from mach. size: 400 mm 250 mm 320 x kg 320 NT Neutral time 0:00 Seamless documentation: ideally equipped for certifications according to GMP, FDA, ISO TS and ISO COMPREHENSIVE DOCUMENTA- TION AND ARCHIVING // You must first identify any potential for improvement to achieve continuous production optimisation. This requires sound information. This information is provided by the ARBURG host computer system (ALS) per click with all the important indicators and clearly prepared statistics, you are always up-to-date. Another benefit is that the available data can also be used during the decision-making process relating to capital investments. Knowledge is always preferable to speculation. \\ 18

19 Continuous data acquisition Long-term, reliable and with no effort: documentation of production and order progress with all events. Logging of batch changes as an order log. Recording of parameter changes with all trends and developments in comparison with the specified setting data. In this way, your production data forms an ideal basis for comprehensive complaints management and seamless quality documentation with regard to your customers. Targeted analysis Whether the productivity of machines and moulds or the cost-effectiveness of orders and items are under examination: a large selection of predefined reports quickly provides help.recorded production data can of coursealso be exchanged using common software tools. This allows you to easily realise individual evaluations. Central networking You can quickly access documents relevant to production, set-up or maintenance, such as inspection plans, instructions, checklists, reports and drawings. The direct link to master data, setting data and orders provides you with efficient document management. Consistently paperless and centrally available always up-to-date. A basis for efficient work: call up information and acknowledge tasks on site, e.g. for maintenance. A basis for energy management: order-based acquisition of energy data. 19

20 APPLICATIONS: DIGITAL IN PRACTICE // Every production facility is unique. And its digital networking is just as individual. The ARBURG host computer system (ALS) with its modular, flexible concept plays a key role and offers you all the freedom you need for your digital transformation. Your data management is simplified and the transparency of your processes is increased. It allows you to utilise your available resources much more effectively whether during order planning, quality assurance, mould management or maintenance. \\ 20

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22 Smart production everything under control ALS is the ideal tool to help you retrieve all important production data for your worldwide locations at any time. Access everything per click: fault messages, downtime causes, production progress, indicators such as OEE, availability and quality rate and not only for ALLROUNDERs, but for all production systems. This creates transparency whether on a smartphone or on a large screen in production. You can configure the views individually depending on the location and purpose of use, e.g. as a machine control station with alarms, as a quality chart with reject rates or as a production overview with orders. Interactive checklists: safely perform and document maintenance work. Comprehensive information: individually configured, clearly arranged and in your corporate design. 22

23 Coordinating maintenance ALS enables you to document the life cycle of the entire equipment in your production system. Documents for maintenance are stored centrally. Shot counts, operating hours, set-up processes etc. are determined automatically and directly recorded. Due dates for maintenance work are constantly monitored and you receive advance warning in good time. Optimise set-up processes From as early as the order planning stage, ALS takes account of the storage location and availability of your moulds, including master mould, inserts and accessories. Automatically generated provisioning lists, warehouse management via touch terminal and scanner support, or online transmission of setting data to the machine: all this adds up to efficient work processes. Documentation according to GMP For order planning you can use ALS to define production combinations (e.g. from machine, peripheral equipment, mould, material) for which there is only one validated data set. You control production enable via user identification with an RFID card and an ACTUAL-TAR- GET comparison via a scan. This means that you receive GMP-compliant process documentation at virtually no extra cost: from the continuous protocolling of process parameters via seamless batch tracking through to long-term archiving of set-up protocols and recalibrations. Validated processes: enabling production via handheld devices. Networked and informed worldwide: ALS is available in numerous languages. 23

24 Scan this code to visit our Media Centre: in-depth, captivating, entertaining. ARBURG GmbH + Co KG Arthur-Hehl-Strasse Lossburg Tel.: contact@arburg.com _EN_GB_ Subject to alterations Printed in Germany 2018 ARBURG GmbH + Co KG All data and technical information have been compiled with great care. However we accept no responsibility for correctness. Individual illustrations and information may deviate from the actual delivery condition of the machine. The relevant valid operating instructions are applicable for the 24installation and operation of the machine.