COMPUTER INTEGRATED DATA LOGGING SYSTEM for CORRUGATED BOX MANUFACTURING INDUSTRY

Transcription

1 COMPUTER INTEGRATED DATA LOGGING SYSTEM for CORRUGATED BOX MANUFACTURING INDUSTRY Electronic Switches (India) Pvt. Ltd; offers complete package from sensor to software such that all the production data from all production machines is recorded in computer. Outputs are available in form of Reports where user can get exact figures of work done by operator so that payment could be made directly as per work. Also various details are available to management for further production analysis. Following machines are generally used in Packaging Industry. 1 STITCHING MACHINE 2 SLOTTING MACHINE 3 FLEXO PRINTING / PRINTING MACHINE 4 ROTARY MACHINE 5 WEIGHING MACHINE 6 PASTING MACHINE 7 COROGATION MACHINE 8 CUTTING MACHINE 9 DIE PUNCHING MACHINE 10 STRAPING MACHINE Above machines are commonly used machines in packaging industries. These machines will be in numbers depending upon the volume of business. Our system covers all the type of machines for recording the production in to computer.

2 THE SYSTEM : - One Data Interface Unit is fixed on each machine with appropriate sensor. - All the Data Interface Units are connected to Controller Interface by a common two core cable. - Controller Interface is connected to a Computer and placed near Computer. - Data Interface Units collects various data such as production, time, status etc and send the same to computer for recording the data. - At computer, data is displayed at Active Screen and stored in a memory. Required reports can be generated using the collected data. - Reports help management while paying operators against work done, reduce idle time, control breakdown time, manage inventory and managing many other activities. - System is based on WINDOWS. - System can be offered for any numbers and any types of machines. - System also has facility to add few machines (2-3) at later stage. - Using system reports, payments can be made to operators for actual work done, such as for total number of stitches, or total number of bundles etc; - Details of report can be imported in EXCEL data sheet. So once the report is available in EXCEL format, user can make his own modified report as per requirement.

3 MAIN FEATURES OF SYSTEM : 1 Out of three shifts any number of shifts can be selected. 2 Timings of shift are selectable. 3 In the beginning of the shift, operator will have to enter his code in the Data Interface Unit. 4 Machine Details are entered in a Master files in the Computer. Name of machine with sr. no. of Data Interface Unit is displayed at Active Screen 5 System can handle any number of products. Product Details such as Product Code, dimensions, weight, no of stitches etc; are to be entered in the system in the beginning. Product code is 4 digits. Product details can be entered up to 18 digits. 6 System records IDLE TIME of machine. Idle time limit can be set by user in seconds. If the production pulse is not received by this time, that machine automatically goes in to IDLE status and computer starts recording idle time of that particular machine. As soon as production pulse is received, Idle status changes to COUNTING. This way idle time of each machine is automatically recorded by the system 7 System also records BREAKDOWN TIME of the machine. During idle status, operator has to manually enter Breakdown Status of machine through Data Interface Unit. Operator also has to clear the Breakdown status after machine is attended and ready for production. System starts counting the production again only in COUNTING status. 8 ACTIVE SCREEN on the computer will continuously display production figures as well as status of each machine. In all there are three status of machine. Status 1 : Status 2 : Status 3 : COUNTING This status shows that machine is working. The same is displayed in green color and window of reading will be in green color. This indicates that the machine is working. IDLE This status shows that the machine is idle and no production is being taken out. This will be shown by yellow color and reading window will be yellow. BREAKDOWN This status shows that the machine is under breakdown. This will be indicated by red color and reading window will change to colour indicating that machine is under breakdown. As the status of machine is shown is different colors, the same is immediately visible. Viewer can immediately know which machines are working, which are idle or under breakdown in just at glance.

4 9 POP UP for each machine is available for details. There is + sign at display of each machine. Pop-up will appear when clicked on this sign. Viewer can see various details of machine and can control some of the parameters through this. Pop-up will disappear when clicked at the sign on the Pop-up. 10 POP-UP offers five selectable fields which can be used for different machines showing different parameters. These are user selectable. 11 System offers total time taken for completing the job. As soon as first production pulse is received by Data Interface Unit, timer starts counting the time. Timer stops when reading at Data Interface Unit are reset by operator. This way total time taken for completing the job is recorded. 12 Idle Time Limit can be set by the user through Pop-up. This can vary as per machine and work. So user can set different idle time limit for different machines. If production pulse is not received during this period, machine goes into idle status. 13 User can reset the readings at Data Interface Unit from the unit itself. Reset facility is provided on the unit to bring the reading to zero. 14 All the Data Interface Units are offered in Metal Powder Coated housing suitable for wall mounting type with switches for entering the data. 15 Reports can be offered as per sample format. DATA INTERFACE UNITS :

5 Data Interface Units are fixed on each machine and they communicate with Computer through Interface Controller. Data Interface Units are specially designed for machines which are used in packaging industry. Some of the machines are as follows : 1 STICHING MACHINES : Data Interface Unit has been specially designed for this application. Unit counts number of stitches. Number of stitches for each product will be different. So there is preset facility on the unit and operator has to set that particular number in the unit. During production when operator starts working, production will be advanced by one count after the set value is reached. There will also be a beep alarm to indicate that stitching for that particular job is completed. Operator will have to enter value for number of stitches every time he changes a product. 1 Operator can set number of stitches required for particular job on the unit itself. 2 Unit gives beep alarm after set number of stitches are completed. Beep helps operator to know that job is completed.

6 3 System informs management the total number of stitches (In addition to the production figures) the particular operator has completed during his shift, so that he can be paid accordingly by management. 2 SLOTTING MACHINE : Depending on material, user will have to set value for number of sheets being punched together. Slotting will be completed after two operations for each job. Reading will increase every time by set value. If set value is 4, output will increase every time by 4. Beep alarm will be given after every two slotting operations. Here operator will have to remember that his bunch should be same as set value every time. 3 WEIGHING MACHINE : 1 If weighing machine gives output in RS 232 format, that data can be sent to Computer for recording. 2 If user wishes to make bundles of fixed weight, bundles can be counted and total weight will be available. In this case operator will have to manually press a switch for increment. 4 STRAPING MACHINE : Depending on type of product, fixed numbers of product are strapped in a bundle. Operator can set this number in a Data Interface Unit. There is one more selection available. Sometime bundle is hold with single strap or sometime with two straps. So selection is available using switch for one or two straps. When one strap is selected, output will be available after completing function of one strap. When two strap is selected, output will be available only after bundle is strapped two times. 5 COROGATION MACHINE : System senses number of sheets. Product dimensions are already entered in the Computer. Using the data, system can offer output length in meters as well as in number of sheets. 6 CUTTING MACHINE : Sheets are cut from a paper roll as per product dimensions. System counts number of sheets. Product dimensions are already entered in a master. If length of paper roll is known, system can offer cross check if sheets cut from the roll are correct in number or not. 7 OTHER MACHINES : Data Interface Units for other machines are offered with special features suitable for those machines for their functions. ACTIVE SCREEN ON COMPUTER : Active Screen on Computer will look similar to screen as below. Here production readings and status of machine is continuously displayed.

7 POP UP FOR EACH MACHINE : Pop up for each machine will look like as follows. Various details of machine will be Displayed and machine parameters can be controlled through this parameters.

8 REPORT 1 : DAILY REPORT

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