Industrial Production System and Solutions for Stone-Countertops

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Ferdinand Brown
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1 Industrial Production System and Solutions for Stone-Countertops

Production of Stone Countertops with SePPS SePPS Industry is a Software Complete-Solution for automatic manufacturing of Stone Countertops or slabs material.

2 Production of Stone Countertops with SePPS SePPS Industry is a Software Complete-Solution for automatic manufacturing of Stone Countertops or slabs material. SePPS Industry aimed at medium and large businesses who want to manufacture their products planned, reproducible and automatically. The program is modular in order to meet the various demands in this industry. It includes the following components: On the next pages we show you a typical example step by step through all processing stations. Interface to Office Management / ERP Drafting, CAD-Drafting Order Management Slab and Stock Management Photo-Capturing Production Planning / Job Preparation CAM-Software for all CNC-Machines Production Controlling / Monitoring Manual Work / Final Check / Packing

Production Database Starting Order A production process starts normally with the recording of the order. The data comes via an ERP-System (for example DIESTEIN) or will be given directly to SePPS.

3 Production Database Starting Order A production process starts normally with the recording of the order. The data comes via an ERP-System (for example DIESTEIN) or will be given directly to SePPS. After this follows the production drafting in SeCAD. Header Data, like customer or material, will be transferred directly to SeCAD. SeCAD itself is not only a drafting software, it creates finished workpieces with material, surfaces, thickness and creates labels. If necessary it also creates bottom sections and laminates. After finishing the customer- and productions drafts can be automatically printed or exported as PDF-Files. All these information are given to SePPS database.

Start Date All workpiece-related data like material, surface, thickness,

4 Production Database Order Management After saving the project in SeCAD you will find all related data in SePPS: Order Data Delivery Date Production Start Date All workpiece-related data like material, surface, thickness, material class and dimension Graphics of all workpieces, which were created by SeCAD

Production Database Slab Management For all orders you need of course slabs.

slabs administration. Like an order, slabs will be handled in SePPS as well.

digitizing Associated blocks Stock value per date Label Printing Managing of

5 Production Database Slab Management For all orders you need of course slabs. For this reason SePPS contains a specially for Stone Industries developed slabs administration. Like an order, slabs will be handled in SePPS as well. SePPS contains all information for slabs: Interface to ERP Interface to slab digitizing Associated blocks Stock value per date Label Printing Managing of vectorised photos Return of usage and waste statistics to ERP Classification Storage (place)

Production Database Stock Management Stocking Slabs is handled by the Stock Management Slabs are now sorted for quick access in the production: Lists with free definable racks (A-Frames, L-Frames,

6 Production Database Stock Management Stocking Slabs is handled by the Stock Management Slabs are now sorted for quick access in the production: Lists with free definable racks (A-Frames, L-Frames, Palettes etc.) Lists for stock positions and stations for racks Rebooking of positions for Slabs over user friendly BDE-masks Request of slabs, racks and positions Communication to High Storage Systems

7 Production Planning I - PCC Now you start with the production planning / job preparation. PCC is the central part of the product planning database. PCC determines on an individual base for every order the handling processes and times. The calculation is based on user defined rules for every workpiece which determines processes for every engine (station) The rules refers to material classes, workpiece thickness, surfaces or profiles which are deposited in SeCAD Stations are CNC-Engines, as well as manual machines and manual workplaces All proposals can be changed manually - f. e. an edge polishing process can easily changed (moved) from an edge engine to a CNC-machine For every workpiece and process the times will be calculated

Production Planning II - Nesting Through TOP it is possible to manage and organize different orders to slabs. In this way it is possible to know - before cutting - how many slabs you will need.

8 Production Planning II - Nesting Through TOP it is possible to manage and organize different orders to slabs. In this way it is possible to know - before cutting - how many slabs you will need. Easy arranging and nesting of workpieces in the office Uniform menu-layout for all type of machines Modules for further functions (Manipulator, Drilling, Milling, Waterjet, Unloading) Connection to SePPS Database Feedback and Return of Remnants

Production Planning III Calendar Sceduling Now we know which slabs we need for the different orders and which engines and stations we need to handle the workpieces and how long it takes, probably.

9 Production Planning III Calendar Sceduling Now we know which slabs we need for the different orders and which engines and stations we need to handle the workpieces and how long it takes, probably. In the next step we fix exactly when the slabs will be cut. SePPS calculates from the deliver date the beginning of the production and allocates the engines with workpieces. SePPS will now arrange these Data automatically to working shifts. An easy calendar in the style of Outlook shows the orders in different views: Order related capacity planning Workpiece and station related capacity planning Engine allocation Calendar views And of course you can change everything manually.

the edge to the workpiece For automatic edge-machines will at the same time the code

10 Production Planning IV Edge Finishing Edges can be defined already in the job preparation. SeEdge generates in background a picture for every edge, which shows the orientation of the edge to the workpiece For automatic edge-machines will at the same time the code generated and loaded automatically to the engine Read Message after Processing Time Recording

11 Production Planning V CNC-Programming All CNC Working Machines can be managed by SeCAM Viewing of Workpiece Data Viewing of the Laser Projection for spanning Workpieces Automatic Loading to engines (if possible) Ready message after processing Time Recording

Production Sawing The production itself starts with the commissioning of all the required

The BDE-Dialog shows all slabs to the operator, all slabs he must provide in his shift or

Through in top nested slabs and the produce date the list will be automatically filled.

12 Production Sawing The production itself starts with the commissioning of all the required slabs. The BDE-Dialog shows all slabs to the operator, all slabs he must provide in his shift or for the selected day. Through in top nested slabs and the produce date the list will be automatically filled. Remnants get automatically the status accessible for further nesting in top. Saws can get slabs manual or automatically loaded. (NC-Programs included) The operator can if needed - modify a NC-Program After Sawing all parts get the status Cutted

SePPS receives automatically (via a interface to the PLC) all part numbers.

13 Production Labelling / Reinforcement After Sawing all parts (Workpieces and Remnants) of the slab gets a label SePPS supports two possibilities to do this: Labelling before Sawing Labelling after Sawing In the full automated variant SePPS receives automatically (via a interface to the PLC) all part numbers. Labelling after sawing: the operator checks the part, print the label and glues it on the workpiece. For palletize and armed parts SePPS has separate Dialogs and Functions.

Production Machines All further processing follows now at the edge finishing engines, the CNC-machining centre or WaterJetmachines. The chronology of all processes and the NCprograms are already done.

If you use a high storage system all workpieces will come automatically to the machine. Otherwise the user sees in the list on which station the part is now and will go.

14 Production Machines All further processing follows now at the edge finishing engines, the CNC-machining centre or WaterJetmachines. The chronology of all processes and the NCprograms are already done. The BDE-screens are individual programed to every engine type. You see only the workpieces who belongs to the process of this engine. If you use a high storage system all workpieces will come automatically to the machine. Otherwise the user sees in the list on which station the part is now and will go. The workpiece will now be scanned and given to the work area of the engine. From this moment until the workpiece is ready on this engine, the time will be recorded. The BDE-Screen shows now what to do with the workpiece in the next step. Edge Finishing Machine shows exactly over a picture how the edge is oriented to part which is in process CNC-Machines will load the program automatically and show the orientation point (neutral point 0,0) After finishing the part becomes a READY Message and the used time will be stored in SePPS. The BDE-Screen shows now the next step (next engine) until all processes are done.

PDF-File Viewing of all Part-Drafts as PDF-File Ready Message after processing Time Recording After the last

15 Production Manual Work The same process takes effect at the manual Work places. Comfortable Viewers controls each station: Gluing Final Check Packing Viewing of the entire Construction as PDF-File Viewing of all Part-Drafts as PDF-File Ready Message after processing Time Recording After the last step the hole order will be set to the status IS READY. Time information for every step of the processing can be viewed at any time over the ERP-System.

Summary SePPS Industry is made up of the following modules Production Database: Material Administration Slabs Administration Stock Administration Order Administration Production

16 Summary SePPS Industry is made up of the following modules Production Database: Material Administration Slabs Administration Stock Administration Order Administration Production Planning for Orders for Workpieces Production Management BDE Terminals controls and monitor each station Approaching for all CNC-Engines Time Recording Special Functions Process-Visualization

17 Ovierview about our Production Modules Customer ERP-System (Offer / Order / Invoicing / Controlling) Office CAD - Drawings Order Management Slab Management PCC-Job Preparation Nesting Bridege- Saws Production - Planning CAM CNC CAM WaterJet CAM Edge- Polishing Preparing Terminal 1 for CNC machines Terminal n for CNC machines Production-Controlling / -Visualization Terminal Edge-Polishing Terminal Gluing / Manual Work Terminal Final check Terminal Packing Slab-Digitizing Production

Product Advantages Reduction of Costs Example: Reducing of slab material (typical 5 %) Reduction of Production time Saving of Employees (typical 30%) Reduction of

18 Product Advantages Reduction of Costs Example: Reducing of slab material (typical 5 %) Reduction of Production time Saving of Employees (typical 30%) Reduction of mistakes Jobs per day: 100 Slabs per day: 150 Price per slab: 200 Working-Days: 220 Material-Costs: 150 x 200 * 220 = Saving by 5%: * 0.05 = per Year

19 Product Advantages Handling One integrated software solution One CAM-System for all machines -> reducing of training

20 Production Monitoring and Visualization Permanent overview of production schedule Monitoring Workpiece-Tracking

21 Our Clients Lechner (Germany) Templer (Germany) Rosskopf (Germany) AKP (Germany) CB (Germany) Strasser (Austria) JetStone (Netherlands) Kemie (Netherlands) Pierre de Plan (France) Coastline (Perth / Australia) The Maker (Perth / Australia) Fervital (Israel)