ARBURG host computer system (ALS)

Transcription

1 Focus ARBURG host computer system (ALS) Active information for efficient production

2 At a glance 1 2 Practical production management: Starting with the simple connection of I/O modules, the modular ALS offers all options for an efficient production organisation. Immediate reliable information: Retrieve key figures anywhere and on any chosen electronic platform. With the ARBURG host computer system (ALS), you have at your disposal a standard-setting high-performance, modular fine-planning tool for your injection moulding production. Tried and proven in practice, this Manufacturing Execution System (MES) provides all the features required in a modern, efficient and cost-effective production organisation. With hundreds of systems already installed, ARBURG has a wealth of experience. This experience flows into the continuous advancement of ALS on an ongoing basis. Here also, Made by ARBURG Made in Germany stands for quality and our familiar future-proof technology. 1 Practical production management ALS is the central tool for the reliable and cost-effective organisation of your injection moulding production. The possibilities for integrating your machine fleet are virtually unlimited: from the simple connection with I/O modules via standardised interfaces for all makes of injection moulding machine through to the host computer interface for ALLROUNDERs. A wide range of modules (overview on the next page) which can be combined as required allow you to perform each individual task with ease. Because your chosen configuration can be expanded at any time, you can be sure of coping with future demands. 2 Immediate reliable information An efficient information management system continuously provides you with current online information on your production centrally and worldwide. Feedback and key figures relating to machines, ongoing orders, shifts and production quality are continuously available. This means maximum transparency, wherever, whenever and however you need it: on PC workstations, info screens in production or on smartphones and tablets. This active information therefore permits you to analyse and make decisions at all times. Set-up operations, as well as mould and machine maintenance can be optimally performed. This is also supported by the central management of all setting data /2017

3 3 4 5 Fine planning: optimum utilisation of available resources. Automatic archiving: effortless, reliable documentation. Easy implementation: rapid system introduction through professional support. 3 Fine planning The special features of injection moulding production, such as machines of different capacities or defective cavities, make reliable detailed planning too complex for conventional ERP, PPS or PDA control stations. You need ALS to enable you to complete such tasks interactively.on the basis of online data, you can optimise batch running times, reduce start-up processes as well as set-up times and downtimes when changing orders. Higher machine capacity utilisation coupled with higher production and product quality enhances delivery reliability. You use an efficient and cost-effective production organisation with which you achieve significant time and cost savings. 4 Automatic archiving With ALS, you can dispense with the time-consuming manual recording of your machine and operating data. Entry errors are therefore reliably prevented. In addition to highly reliable information, you have more time for value-adding activities such as production planning. ALS helps you identify potential for improvement and carry out targeted optimisation measures. Additional benefit: the continuous and long-term documentation makes audits and certifications significantly easier. Business example: injection moulding production with 20 machines 5 Simple implementation We offer you individual consulting to help you devise the ALS system solution to meet your needs. Installation and on-site support with the implementation through to the comprehensive training of your employees and administrators are provided as a matter of course. This is the only way to achieve a simple, trouble-free system implementation, immediately ensuring high acceptance in the company along with the required added value. This means that your investment pays off from the start and yields the fastest possible return. Production time Working time Data acquisition per machine/day: No manual data entry required (- 15 min.) Downtime per machine/day: Malfunctions detected immediately (- 3 min.) Set-up time per order: Online transfer of data records (- 6 min.) Potential savings per year 250 working days/10 set-up operations per day 250 hours 250 hours 500 hours 1,250 hours 250 hours 1,500 hours 09/

4 At a glance Functional module Interface module Required module Dependent module Practical production management: The individual modules of the ALS can be freely combined and eliminate the need for separate programs e.g. for maintenance. Information centre 609/01 Base Core module for data acquisition, production overview and mould management 610/06 Remote Remote maintenance via Internet connection 610/20 Mobile production Mobile MDE or PDA terminal 610/21 Mobile monitoring Production information on mobile devices 610/22 Info for individual info screens in production 610/27 Mobile maintenance Maintenance and service terminal for mobile devices 611/0x I/O modules Connection of any machines and workstations via signals 611/08 Web I/O condition Recording of ambient conditions 611/09 Web I/O alarms Output devices for central alarm signalling 611/11, 14 ALLROUNDER interfaces Connectors for ALLROUNDERs with SELOGICA 611/15 Energy visualisation interface Licenses for connecting up to 10 Econ sens3 devices 612/xx Machine interfaces Connectors for injection moulding machines and protocols of various manufacturers 612/21 Device Connector Data recording of systems via network 612/22 OPC UA connector Data acquisition via OPC UA 613/01, 613/05 Clients for PC workstations, laptops etc. 613/20, 21 Terminal for order messages or mould provision Documentation/archiving 610/01 Reports Order, item, mould and machine-based evaluation, data export 610/08 Progression Display of events such as machine status, shift change and cavity change 610/10 Set-up log Daily back-up of SELOGICA set-up log 610/12 Documents Linking of documents with orders, programs, maintenance and much more. 610/14 Data warehouse Save states and events in separate database 610/15 Production log Permanent archiving of process parameters 610/19 Events archivelong-term archiving of event data (alarms, downtimes etc.) in separate database 610/25 Energy visualisation Acquisition and documentation of energy data Production/resource management 610/03 Orders Order planning, graphic planning chart, schedule monitoring 610/05 ERP interface Linking with ERP, adoption of order data, ongoing feedback 610/11 Maintenance Maintenance plans, monitoring, due dates, documentation 610/13 Groupware feedback in the event of faults or maintenance, cyclical reports 610/16 Production variants Material planning of alternative moulds, taking account of machine performance 610/17 Resource conflict Monitoring of moulds for double assignment 610/18 MES interface Data exchange with production management systems 610/23 Batch Documentation of batch changes in order logging 610/24 Material staging interface Data exchange with systems for material provisioning 610/26 Maintenance verification Verification of maintenance tasks /2017

5 Base 609/01 Remote 610/06 Material Staging Interface 610/24 Batch 610/23 ERP- Interface 610/05 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 Quality assurance 610/02 Programs Program management and transfer between machine and ALS 610/04 Quality Statistical process control (SPC) via actual process values, process signals, interface to quality assurance systems 610/09 Programs plus Parameter lists, full text search, program comparison for ALLROUNDERs with SELOGICA control systems 09/

6 Powerful information centre Record data everywhere: multi-function terminals also integrate manual workstations. 1 Integrating all machines For ARBURG, all really means all! Regardless of the manufacturer, year of construction and production process, all the injection moulding machines and production systems can be integrated in the high-performance ALS information centre. The following options are available: Multi-function terminals for older machines and manual workstations I/O modules for simple connection of any machines and systems Standardised interfaces for injection moulding machines of all makes Host computer interface for ALLROUNDERs The SELOGICA machine control system interacts optimally with ALS, if e.g. direct access to screen pages, direct recording of fault causes, exchange of setting data or comparison with the order list are involved. Flexible and rapid response to production requirements is the order of the day. The powerful ARBURG host computer system (ALS) provides you with real-time access to your production data, worldwide across all your locations, even enabling remote maintenance. A direct flow of information is ensured through connection to your company-wide production planning system (PPS) or enterprise resource planning system (ERP). You benefit from complete vertical integration from the machine through to material planning, purchasing and sales. Management Productionmanagement ERP/PPS ALS Production Ethernet Ethernet 1 Further information: SELOGICA control system brochure /2017

7 2 Central data acquisition ALS enables the central management of part, mould and material master data. This enables you to perform real-time production planning down to the minute through the online recording of order statuses, machine states, process parameters and alarm messages. With this precise information, you are able to quickly and flexibly respond to the constantly changing requirements. Optimum cost-efficiency in production is thus ensured throughout. The combination of machine and production data acquisition (MDA and PDA) allows you to make target/ actual comparisons to optimise processes and reduce set-up times. All occurring events are immediately registered via continuous status monitoring. 3 Comprehensive data provision Constantly up-to-date production data benefits your planning system. Order data is adopted by the planning system, feedback on order progress is provided by ALS. 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. 2 Central data acquisition 1 3 Comprehensive data provision Integrating all machines 09/

8 Preventive quality assurance 1 Convenient archiving of setting data ALS facilitates the fast retrieval of the relevant data for a certain production combination, such as machine/peripheral/mould/material. As well as the setting data, setting logs and the corresponding screen pages can be archived simply and reliably. Furthermore, the creation of parameter overviews from archived setting data is just as quick and easy as the direct comparison between two data records with detailed indication of potential differences. Documentation of the settings can thus easily be achieved during a batch or a running order. Central access: optimised and approved setting data. Know-how is virtually priceless. Consequently, you should treat your setting data with the greatest of care. The ARBURG host computer system (ALS) provides you with secure collection and archiving of your important data. Only the most recent, optimised and approved change status reaches your machine; the possibility of outdated setting data being used is excluded. Diskettes and memory cards are a thing of the past. You receive fully reproducible product quality and minimise complaints. Excellent conditions for successful audits and certifications. 1 Convenient archiving of setting data /2017

9 2 Active improvement of product quality The quality of your production is traceable thanks to the monitoring and documentation of changes in the production process, through the recording of actual process values. The product-specific management of reference values and tolerance bands for the current actual values contributes towards increased production and product quality. Warnings can be output with regard to imminent quality deviations. You can then respond quickly and proactively, without having to interrupt production. 3 Verifiable process quality You can provide evidence of the quality of your production process through the order-specific archiving of the actual process values. Detailed long-term analyses, statistical evaluations and proof of process capability, for example according to ISO TS 16949, can be implemented. Furthermore, close networking with quality assurance systems is possible. 2 Active improvement of product quality 3 Verifiable process quality 09/

10 Efficient production and resource management Ideal for unmanned shifts: active, instant feedback via . 1 Central order management Your order planning prompts the provision of the necessary setting data, the relevant mould and the required material. The setting data is transmitted directly to the machine when production of the order commences. You ensure a high degree of integration, interaction and automation of your production facility while ensuring intelligent production. 2 Machine capacity planning By planning your machine capacity down to the last minute via ALS, you achieve comprehensive time and cost savings: perfect utilisation of available capacities, precise information on the relevant manpower requirements, minimisation of set-up times and also the co-ordination of necessary interruptions in production all of this is made possible by ALS. The special features of injection moulding production such as The clearly structured order planning and monitoring via the ARBURG host computer system (ALS) enables efficient production management. The direct assignment of orders to machines and the creation of order queues via the planning tables ensure a high degree of planning reliability. The proactive fine planning and co-ordination of machine allocation, order situation, production deadlines and unit volumes as well as maintenance work lend transparency to even the most complex production requirements. You are able to manage the available production resources reliably and with ease. For ARBURG, smooth, automatic data exchange with planning systems such as SAP is a matter of course. Machine capacity planning Reliable delivery Maximisation of availability Central order management /2017

11 family moulds, defective cavities, mould inserts, master moulds, additional peripherals or machines with different performance can be incorporated into the fine planning. Targeted information exchange also supports departments such as warehousing, mould making or service in organising their operations. 3 Reliable delivery The current scheduling status at a glance: fast and specific order clarification with active display of bottlenecks and potential delivery delays means you can provide information on an ad hoc basis. Countermeasures can be implemented in good time and production and delivery deadlines can be reliably met. This preventive processing of orders ensures a high degree of customer satisfaction. 4 Maximisation of availability With ALS, you can centrally manage and document your maintenance orders for moulds, machines and peripherals. The continuous monitoring of due dates and automatic reminders for forthcoming work via text message, or info screen protect you from unscheduled machine downtimes. In this way, you secure your production quality in the long term through preventive maintenance

12 Comprehensive documentation and archiving Well-founded information: data evaluation at the press of a button. 1 Continuous data recording ALS offers you long-term documentation, which is reliable and requires no effort on your part: Of production sequences with recording of all relevant events. Of order progression with documentation of all events during production of the order, including batch monitoring in the form of an order log. Of parameter changes with recording of all trends and developments in comparison with the specified setting data. These measures ensure your production operations are more transparent. ALS therefore provides you with an ideal basis for comprehensive complaints management and seamless quality documentation with regard to all your customers. You are ideally equipped for certifications according to GMP, FDA, ISO TS and ISO Ensure ongoing production optimisation through the continuous identification of potential improvements. Well-founded information forms the basis for professional decisions. This well-founded information is provided by the ARBURG host computer system (ALS) with all the important key data and statistics, you are always right up-to-date. The fact that the recorded data is presented in a clearly structured manner at the touch of a button makes ALS all the more attractive. A significant benefit is that the available data can also be used during the decision-making process relating to capital investments. Knowledge has always been preferable to speculation /2017

13 2 Targeted analysis Targeted analyses become child s play. Whether the productivity of machines and moulds or the cost-effectiveness of orders and articles are under examination, the ALS modular production management system helps you complete this with a high degree of clarity. For this purpose, a large selection of predefined reports is available. Moreover, data exchange for the further processing of recorded production data using standard software tools is of course always possible. This allows even highly specific evaluations to be made simply, quickly and reliably. 3 Central document networking ALS provides fast access to production-related documents, such as work instructions, test schedules, parts lists and drawings. Through direct linking to master data, setting data and orders, the current availability of documents and the absence of paperwork, you receive an efficient information management system. Comprehensive and always centrally available. 1 Continuous recording of data Targeted analysis 3 Central document networking 09/

14 Application examples 1 2 Individual info screens: free selection from various widgets provides for on-site transparency. Worldwide networking: ALS is available in numerous languages. ALS offers a wide variety of functions to enable you to implement your specific requirements for an efficient and cost-effective production organisation. Thanks to the flexible, modular concept, precise adaptation to different applications is comprehensively ensured. This may involve quantity recording, simple connection to I/O modules, detailed fine planning of available capacities or management of the mould store. And you can be sure of one thing: ALS considerably simplifies your data handling and allows you to optimise your production in a targeted manner, including time and cost saving. 1 Creating transparency From smartphone through to large flatscreen in production: with ALS, you can configure customised info screens browser-based and completely platform-independent. Depending on the location and purpose of use, any number of different info screens can be combined, e.g. for alarms as a machine control station, for increased reject rates as a quality chart or for orders as a production overview. In addition, a wide range of graphic design options allows you to present the collated information in your corporate design. 2 Access to all locations ALS is the ideal tool to help you retrieve all important production data for your worldwide locations. A standard network connection is all you need to be able access fault messages, downtime causes, production progress, key figures such as OEE, availability and quality rate at the touch of a button. And not only for ALLROUNDER injection moulding machines, but for all production systems. However, remote access via ALS is also a useful service tool. Quick assistance from ARBURG Customer Service is therefore instantly available to you. ALS modules in use: Web I/O alarms Info Progression ALS modules in use: Mobile Programs Reports /2017

15 3 4 5 Interactive checklists: a useful aid so that nothing is forgotten. Automatic mould provision list: direct feedback via touch terminal. Validated processes: production release via handheld unit. 3 Coordinating maintenance With ALS, you can document the maintenance history of machines, moulds, peripherals and other equipment in the long term and extremely reliably. Shot counts, operating hours, set-up processes etc. are determined automatically and directly recorded. Due dates for maintenance work are constantly monitored you receive advance warning in good time via text message or . In addition, ALS supports you in the performance and documentation of maintenance work, e.g. instructions, checklists, reports or electronic signatures can be stored. 4 Optimise set-up processes Even at the order planning stage, ALS takes account of the storage location and availability, including master moulds, inserts and accessories. Current provision lists are automatically generated. Mould management, a touch terminal for stock movements and scanner support are also provided. Moulds can therefore be provided particularly quickly and efficiently. ALS transfers the data record of the next order online to the SELOGICA machine controller. Set-up personnel are therefore provided with the mould and data record in good time at the machine and can start the set-up immediately. 5 GMP-compliant documentation On the basis of a central machine control, you can use ALS to define production combinations (e.g. machine-peripheral-mould-material) for order planning. This means that there is only one validated data record for each production combination. You can control production release via user identification with an RFID card and an ACTUAL-TARGET comparison via a scan. ALS then offers you GMP-compliant process documentation at virtually no extra cost: from the continuous logging of process parameters via seamless batch tracking through to long-term archiving of set-up logs and recalibrations. ALS modules in use: Maintenance Groupware Documents ALS modules in use: Terminal Programs Orders Reports ALS modules in use: Mobile Programs Orders Quality Set-up log Batch 09/

16 ARBURG GmbH + Co KG Arthur-Hehl-Strasse Lossburg Tel.: contact@arburg.com With locations in Europe: Germany, Belgium, Denmark, France, United Kingdom, Italy, Netherlands, Austria, Poland, Switzerland, Slovakia, Spain, Czech Republic, Turkey, Hungary Asia: People s Republic of China, Indonesia, Malaysia, Singapore, Taiwan, Thailand, United Arab Emirates America: Brazil, Mexico, USA For more information, please go to ARBURG GmbH + Co KG The brochure is protected by copyright. Any utilisation, which is not expressly permitted under copyright legislation, requires the previous approval of ARBURG. 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 installation and operation of the machine. ARBURG GmbH + Co KG DIN EN ISO certified _EN_GB_ Subject to alterations Printed in Germany