Caterpillar Torreon Mexico VersaCall Data Input - Capturing OEE Information CNC Machines I. VersaCall Modules Data Input & s Receives Inputs Directly from CNC Machine Wired Linked w/serial Cable Data Input Module Screen Input Operator Bar Code Scanner Input 4 Internal Switch Contact Machine Interface o Counts o Equipment Operational Status o Fault Codes II. Input Sources For OEE Reporting Note: The Shift Start/ Stop Times and the Schedule Downtime for a Production Period are Input in Look Up Tables in the VT2000 System. Line Supervision or Production Management Usually Inputs this Information in Advance of Production. Production Run Information Input at the Start of a Production Run Information Input Source Lot Number / Production Run Part Number Optional: Employee who Performed the Set-Up Optional : Employee who Performed Production Run Pre-programmed screen requesting Lot Number comes up when you start production Pre-programmed screen requesting Part Number comes up when you start production Pre-programmed screen requesting Employee Number comes up when you start Set-Up Pre-programmed screen requesting Employee Number comes up when you start Producing Parts Operator Input Bar Code Scan or Keys In on Key Pad Input Source can be pre-programmed Operator Input Bar Code Scan or Keys In on Key Pad Input Source can be pre-programmed Operator Input Bar Code Scan or Keys In on Key Pad Input Source can be pre-programmed Operator Input Bar Code Scan or Keys In on Key Pad Input Source can be pre-programmed 1
Availability Information Input Source CNC Machine Available for Production Producing Parts CNC Machine Down Scheduled CNC Machine Down- Unscheduled Machine Idle [ Available for Production] Switch Contact # 1 from the CNC machine Count Switch Contact #3 or there is an optional switch contact [#4] output from the CNC Machine Input Table Shift / Schedule Downtime Switch Contact #2 from CNC machine Calculated - Available Time less Producing less Downtime machine machine available time is automatically captured machine producing parts time is automatically captured Line Supervisor maintains shift data and scheduled downtime machine machine downtime VT2000 Software Performance Information Input Source Actual Quantity Output by Defined Time Period Standard Quantity Output by Defined Time Period Counts - Switch Contact #3 Part Number input at the start of production machine VT2000 Software calculates VT2000 Software with Data Lookup Manager retrieves the Standard and calculates the Std Quantities Quality Information Input Source Total Parts in Production Count Switch Contact #3 machine capture total counts for Quantity of Parts No Shippable for Production Run / Lot Number Entered into the Data Input Module at the end of the Production Run or entered into the Database at a later date for the production run production run. Either the operator at the end of a production run or quality engineering at the later date 2
III. Capturing Production Run Information Data Input Module Performance Activity Information Capture Production Performance By Employee Hour Shift Part Number Production Run Work Station or Equipment o Production Time by time period day or shift o Availability by time period- day or shift o Idle Time by time period day or shift Real Time Performance to Standard With immediate communications options when Standard is not being met. Set-Up Time Cycle Time Takt Time Scrap Standard Communications Optional for the Future Number of Incidents Response Times to Incidents The automatic capture and documentation of the response time to floors issues has proven to significantly change the way that floor support respond to issues. Set-Up Production Pre-Run Check List this can include measurement information Total Set Up Time Set-Up Disruptions [i.e. Set-Up Unscheduled Downtime by Reason Code] Counts Employee Performance to Standards Employee Total Units Produced [Machine Count] Total Time Total Scheduled & Unscheduled Downtime by Reason Code 3
Total Production Time Scrap Count Scrap by Reason Code Performance to Standard Counts Equipment Interfaces Typically the VT2000 only requires (2) two equipment interfaces to the input modules for the capture and profile of performance information. These can be software switches to switch contact inputs see Section VII interfacing the VT2000 Input Modules to Equipment. 1. Counts 2. Machine in Production Output Mode 3. Optional - Scrap [ This can be either manual or equipment input] Input Screens Examples Data Input Module Note: These are only examples these screen are complete programmable In Spanish in any sequence or format that you require. Main Menu Selecting On of the Presses brings up the following menu Start Production Run Production End Production Break Selecting Start Production CNC 401HE Set Up Lot Number Part Number Employee Number Start 4
After the Entering of the Set-Up Information and Press Start Pre-Run Check List In Set-Up Mode Set-Up Disruptions End Of Set-Up Selecting Set-Up Disruptions [This is an option available] Set Up Disruptions Tooling Incorrect No Materials Alignment Issues Selecting one of the Set-Up Disruptions Will Activate the Item Selected and that will have to be closed out upon the conclusion Selecting End of Set-Up Concludes the Set-Up Activity and You Return to the Main Menu Start Production Run Production End Production Break Lunch Call Select Run Production Starting Production Employee 5
Running Production Screen Counts can Appear on Data Input Module Screen Running Production Production Count Production Running Downtime Occurrence Machine Down Idle No Material Maintenance Issue No Cerveza Note: Lock Out If the switch contact is triggered that the equipment is not operational, you can configure the equipment [this requires hardware as well as software] that a reason code must be selected before the equipment can be restarted. It will not re-start unless a reason code is select and all the time for the duration is assigned to the reason code. Ending Production Select End Production Start Production Run Production End Production Break All the Production Performance is Capture in the VT2000 Control Unit and Is Available to Display Real Time or for Reporting. Ending Production Terminates All Data Collection Or Scrap can be input at the conclusion of production Choose to Capture Scrap at the End of the Production Run or Enter Scrap Qty In Database at a Later Date After Scrapped is Entered the Software can be programmed to end production automatically 6
Total Qty Scrapped Reasons: Burrs Material Tooling Alignment Nicks Operator Run Off Qty Later IV. Instructions for Installing Data Input Module For each of the 46 Data Input Modules Installation Instructions will be Provided 7
V. Communications Can Be Linked to D.I. Function Keys Stack lights are integrated with the Data Input [D.I.] Module These are Function Keys Any One of the Keys can be programmed to call for support just like to call box. Pressing the Call Button a predefined list of persons to call will appear on the screen. You scroll down and select. The same set of activities with total time and response time is captured 8