To overcome the issues presented by batch processing, we have developed a number of innovative solutions, these include:

Transcription

1 EzOpt SQL is a powerful companion to GlassPro SQL providing a production system for glass processing, tempering and sealed unit manufacturing, incorporating: Production planning Glass optimisation The suite of programs uses a powerful Microsoft SQL server database. Ezopt SQL can be run single or multiuser production runs optimised on one workstation can be edited, re-optimised, printed or transferred to the cutting table from another. It can be used stand alone with its own order entry system. or can work from the output generated by GlassPro, Windowlink, WindowMaker, Window Designer, Window Star and a variety of other programs. Breakages can be added directly into subsequent production runs if required. Bevelling and polishing clearances can be added to order lines after they have been imported to reflect the different add-ons required for different polishing and CNC machinery Production Planning & Batch Control EzOpt SQL will normally be used to optimise individual batches of orders as they are passed to it. The benefits of this approach are that it ensures that all the orders in a batch are kept together for processing. However, the downside is that it does not always achieve the best yield from optimisation because the racking systems used restrict the size of batches and consequently the number of pieces available to the optimiser. Additionally, there is usually an offcut on the end of each batch run which has to be removed from the table and stored for subsequent reuse or for cutting production breakage replacements. To overcome the issues presented by batch processing, we have developed a number of innovative solutions, these include: Adding and adjusting polishing trims Sub-batching taking bigger batches and breaking them down into smaller linked batches where the o ffcut from the last plate of one sub-batch become the first sheet of the next sub-batches.

2 Last Sheet Offcut First This option takes into account the problems associated with removing offcuts from the table and storing them until required. It works with full height offcuts from the last plate of a run. This is automatically used as the first plate of the next run of the same glass type and the resulting pattern is incorporated back into the last pattern of the run from which the offcut came, effectively creating a continuous production environment with breaks to ensure orders can be completed in sequence Production Runs by Material Type or Product Category- This option offers alternative methods of optimising by grouping individual un-optimised order lines by date required sorted into glass type or alternatively by product group, spacer group, decorative group, and process group. Instead of optimising batches of orders you will create Production Runs chosen from the categories and dates required, tailored to your shop floor priorities and requirements. When used with GlassPro and GlassPro SQL, orders are checked, allocated a delivery date (which may differ from the customer s required by date) and a production date, and are then flagged as ready for production and transferred to EzOpt SQL ready for processing. Different production dates can be allocated to each order line allowing Georgian and Leaded units to be scheduled for production ahead of standard units. Production planning The production planning module takes a spreadsheet approach to production batch planning. It shows un-optimised work with the column headings listing the production day (or if you prefer the delivery day) and the rows analysing the order lines into categories, detailing the number of pieces and area of glass. The system analyses individual un-optimised order lines using a set of pre-defined criteria. Products can be grouped by glass material, product type, decorative effect (Georgian and leaded) spacer category (aluminium bar or warm edge), and processing categories (shapes, argon filled, polishing, bevelling, etc.). From the list of groups selections can be made to create a production run for optimisation. The various groups can be individually selected or combined together for inclusion in production runs. Groups from subsequent production dates can be included within a production run for the current day allowing the leaded and Georgian units for tomorrow to be included in a standard unit run for today. Limits on the number of units in a production run can be applied to suit the space around the cutting table where slot or harp racks are used. This means that a large group can be divided into several runs. As the runs are created the items are excluded from the list of outstanding production. Runs can be cancelled and the items added back into the list of outstanding production. Once runs are created they are optimised and processed to the cutting table, spacer bender, etc.

3 In the example to the right we can see all the glass required each day, and can choose to optimise together all the glass of a particular type from the orders due for delivery say tomorrow and the day after. This method gives good yields because it allows us to adapt the sizes of our runs and combine the glass required for several batches together in a bigger run. The planning module also allows you to view orders by production date or delivery date and combined with the order tracking system shows you the current status of orders and order items as they pass through the assigned work centres. Racking and Piece Identification The racking systems in EzOpt SQL have also been developed to accommodate these new production run processing routines. Because you are selecting parts of orders rather than complete orders for inclusion in a run, there needs to be a way of putting the orders back together again for delivery after assembly. So we have introduced a second rack number, the first is the run rack number and the second is the delivery rack number. Adding ID codes

4 Once a run has been selected from the outstanding groups, all of the items within the run are allocated a rack or slot number. The rack number can be allocated per unit (2 pieces per slot) or leaf, and the sequence can be ascending or descending, chosen from delivery date, delivery route, customer, order number, glass perimeter, glass width, longest side or spacer type. Up to five sequences can be applied, i.e. customer (A to Z) by order number (lowest to highest) by perimeter (largest to smallest). Additional criteria can be applied to omit single s, sealed units, annealed or toughened. Filters can be applied to product groups and these groups can be separated within a rack sequence or put on separate racks. The delivery rack number is a number to be used after assembly to put the orders back into order sequence ready for delivery. This rack number is allocated to the incoming orders before they are selected for production runs. This is done by selecting whole orders. You can view orders by batch, production day or delivery day, sorted into customer sequence. You can select orders and allocate the additional rack number using a sequence chosen from the same criteria detailed in the previous paragraph. The delivery rack number is allocated before the run rack number. Both rack numbers would normally be printed on the labels. Optimisation EzOpt SQL optimises from up to 20 stock sheet sizes simultaneously to give you the best glass utilisation possible. The results can be viewed on screen and the batch accepted or rejected. Individual patterns can be excluded from a run, and the offcut on the last sheet from the previous run can be used as the first sheet for the next run (see below for further details). If you are not happy with the yield, additional pieces or whole orders can be added to the batch and it can be reoptimised. If you toughen your own glass, then the toughened and annealed glass can be linked together for processing, they will be cut from the same stock sheets but separately identified and racked. Optimisation Results are displayed on screen for checking EzOpt SQL allows you to select from the following optimisation methods - mixed or repeat cutting. Mixed cutting will optimise each leaf of a sealed unit separately, and by giving the optimiser more pieces to work from, this method generally produces the best yield. To assist with pairing the individual pieces after cutting there are a number of racking methods. Repeat cutting offers easier glass handling because it optimises one leaf of a sealed unit only, and each stock sheet cutting pattern is cut twice. The pieces broken out from the first sheet are stacked on an A frame, and the pieces from the second sheet are stacked on the same A frame alongside the first stack. Piece 1 on stack A pairs with piece1 on stack B and so forth. The clear leaves matching a pattern, Low E, tint or other glass are kept back by the

5 program and optimised at the end of the run. EzOpt SQL supports X,Y, Z and W cuts giving excellent results. It also allows you to specify that starting rows/strips should have 2 similar size pieces

6 EzOpt SQL incorporates several racking solutions to assist with the pairing and assembly of units and to aid the loading of trolleys for the transport and processing of glass within the factory these involve the use of either A frames or Slot ( Harp ) racks. EzOpt SQL prints a pictorial representation of the cutting diagram with cutting instructions, which can include detailed hand cutting instructions if you do not have an automatic cutting table. Waste Management can be controlled through offcut reutilisation or through the last plate first option. The offcut reutilisation option allows you to save the offcuts from one optimisation run to be used in subsequent optimisation runs. This system is ideal if your cutting table is equipped with an overhead offcut storage rack. The last plate first system takes into account the problems associated with removing offcuts from the table and storing them until required. It works with full height offcuts from the last plate of a run. This is automatically used as the first plate of the next run of the same glass type and the resulting pattern is incorporated back into the last pattern of the run from which the offcut came. So when the plate is cut it is contains both the last pieces from run A and the first pieces for run B. This is clearly identified on the cutting pattern and the operators can see where the break between the runs occurs to enable them to stack or rack the glass separately. If you are using slot racks for pairing units the pieces from run B will have different rack numbers from run A. Using this method there are never any offcuts to be removed from the table, storage and damage to offcuts isn t a problem and your yields are significantly improved. It effectively creates a continuous production environment with breaks between groups of orders to ensure orders can be completed in sequence. Last pieces from run A w ith rack numbers for that run First pieces for run B w ith rack numbers for this run

7 Batch Management allows you to divide bigger batches into sequential runs or sub-batches which again can pass the last plate offcut through to the next sub batch as the first plate cut. Sub-batches can be differentiated by glass product group, glass thickness, spacer type and rack number. If sub-batches are split by rack number then you can specify a maximum number of slots to allocate for each sub batch to accommodate the number of trolleys you can get around your cutting table Comprehensive glass and spacer material databases are held in EzOpt SQL to provide information for order entry, optimisation, printing labels and reports and linking to glass cutting tables and spacer benders/chop saws. EzOpt SQL prints spacer bar cutting lists in the same sequence as the glass is broken out, or in rack or order sequence. It also prints separate hand cutting lists of any glass which is not going to be optimised (patterned glass, etc.). EzOpt SQL prints bought-in glass lists for toughened or laminate glass (if you do not have the facility to produce it yourselves). These reports include racking instructions to enable your suppliers to add the information to their glass labels so that your staff can rack the incoming glass ready for production andto match the spacer bar cutting lists or saw cuttin g instructions. EzOpt SQL can be linked to Lisec, Bystronic, Bottero, Global Glass Technology, Intermac, Contract Developments Berlyne Exeldee, Powergrind, Coopmes, Daura, and many other automatic cutting tables and to Lisec, Ruikan, MTL and a variety of other spacer bar benders and spacer chop saws. EzOpt SQL Glass label printing is a particularly flexible tool. Labels are designed using Seagate s Crystal Report Writer. Crystal is a powerful report writing program which gives you the ability to design your own label layout. Labels can be printed for each piece of glass or for a finished unit. Labels can be produced any size and can be printed singly or side by side (2 up) on laser printers using low tack labels on A4 sheets, or can

8 still be printed on continuous labels using a dot matrix printer Labels can incorporate your logo in full colour, and for specified customers the software can automatically replace your logo with your customers own logo a valuable sales tool for you because the customer does not have to remove the label from the unit before sending it out. It also helps your staff to identify the orders on the shop floor and reduces the incidence of items for a different customer being put on a delivery stillage. Labels can incorporate your BS Kitemarks.

9 Labels can include colour highlights to identify certain characteristics such as: A different colour for each delivery route, delivery date or day of the week A different colour or symbol for each customer A colour or highlight for different glass types, spacer types or to identify processing requirements Selective text based on the product i.e. Glaze this Side In (or Out) on K or Softcoat units Bar codes can be printed to drive processing machinery and for use with the GlassPro Production Tracking software. Labels can incorporate uglass Ratings and uwindow ratings including your customer s own WER Energy Rating graphics

10

11 These are examples of EzOpt SQL production reports, hand cutting lists for any pattern glass and laminates which are not going to be cut on your automatic cutting table and a bought in glass list to send to your toughened glass supplier. Spacer bar cutting list Production Report List of glass to be hand cut Bought in toughened glass list

12 Production Tracking This module is provided through GlassPro SQL and enables you to automatically gather data regarding the status and location of work in progress from the shop floor and update the GlassPro database. It can be implemented in a variety of ways: 1. Using bar codes printed on glass labels, it allows you to monitor individual pieces of glass and completed units passing through various points on the shop floor. It is designed particularly to track glass or units completing production and therefore to identify shortages before delivery stillages are loaded, and enable remedial action to be taken. Monitoring should take place on the shop floor towards the end of production at the end of the cutting line, toughening furnace, unit assembly line or at a quality control check point and in the despatch area. 2. Using bar codes printed on Works Orders to automatically progress the job as a whole through the factory production stages You will need one or more computers on the factory floor connected to your network to act as collecting points for the data. A single computer with 2 serial ports can run the base stations and guns for two work centres. Features:- -Set up work centres for tracking e.g. cutting line, toughening furnace, unit assembly, quality control or dispatch areas -Print bar code identification on each works order and/or glass label -Bar codes can be scanned at reading stations -System will record each item passing through the work centres and final job completion. -The order enquiry programs have been extended to show a list of items due to pass through the work centre and the quantity scanned so far, therefore giving the status of the job and of each item on the job. -Production reports include:- List of items scanned by job by day List of outstanding items by job by day List of jobs completed for day List of items scanned by job by week List of jobs completed for week List of outstanding items by job by week -Screen enquiry will be available at the work centre level showing the jobs/items scanned at the work centre time and date You will require a computer terminals on the shop floor networked back to the main office system. There are two types of scanner available a standard industrial scanner, linked to a computer by a 2 metre cable which can plug into the serial port of the computer system. When not in use the scanner sits in a charger unit. Alternatively, a cordless industrial scanner, which communicates with a base station linked to the computer by a 2 metre cable which can also plug into the serial port of the computer system. The cordless scanner can operate up to 50metres away from the base station and when not in use, it sits in the base station which also serves as a charger unit. Cordless scanners incorporate a display to tell the operator that a scan has been successful and display the order/item that has been scanned.

13 Other EzOpt SQL Options: Shape Cutting - This option allows you to enter shapes directly against specific order lines or to transfer shapes from GlassPro s standard shape library. Cutting trims can be added to the shape as required. These shapes are included in the optimisation runs with rectangular pieces and the cutting data for the shapes is downloaded to your cutting table if it has a shape cutting facility. DXF Cutting - This option allows you to attach DXF files created in AutoCAD or from a template reader on your cutting table or CNC processing machine against specific order lines. Cutting trims can be added to the shape as required. The shapes derived from these DXF files are included in the optimisation runs with rectangular pieces and the cutting data for the shapes is downloaded to your cutting table if it has a shape cutting facility. Offcut Re-utilisation - Offcuts can be labelled and added to the list of available stock. The system will then automatically use these offcuts in subsequent optimising runs Cutting Filler Pieces - If you carry stock of standard sizes for mirrors, louvers, fanlights, etc, these can be set up in a library and slotted into cutting patterns to improve the optimisation. Tempering Bed Optimiser - Secondary optimising of tempered glass bed loads for better yields and lower energy consumption. EzOpt SQL will optimise any toughened glass for the bed of the toughening furnace, and incorporates sophisticated racking instructions to help the operators sequence the glass from the cutting table to the furnace to arrive at the furnace in the right sequence for loading. The furnace loading instructions can be printed on the label or displayed on a console over the furnace input conveyor. Console Cutting Instructions The optimised cutting plans with breakout and racking instructions can be transferred to a computer on the shop floor and displayed on a large monitor situated over or alongside the breakout table. For further information, phone: Highway Electronics Ltd Unit 2, Metherell Avenue, Brixham, Devon, TQ5 9QB Tel: Fax: enquiries@highwaysoftware.co.uk