F CTORY FR MEWORK. Product Description. USA.com

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Factory Framework Shop Floor Management System (SFM) SFM closes the communication gap between the Shop Floor (machines) and the planning level (ERP). In a typical manufacturing plants, these two levels evolve on separate paths, and integrating them is left to the production office. The attempt to synchronize what ERP says with what the Shop Floor does leads to islands of information and excess paperwork. The data ERP needs is often late, insecure, or overwhelming. Factory Framework SFM revolutionizes this process, bringing transparency and flexibility by integrating the following processes: Integrates seamlessly into the existing ERP system (complimentary to SAP ERP). Collates detailed, real-time data supply for ERP, giving the planning level the ability to determine key figures, order progress, and perform accurate cost calculations. Provides flexibility in further processing of the collected data in ERP by working with your company s existing ERP technology. Offers flexible evaluation and reporting options by bi-directional data transfer to and from the ERP system (e.g. SAP Business Warehouse). Enterprise Resource Planning ERP Adapter Detailed Scheduling & Control Order Management Production Data Management Alert Management SFM Performance Analysis & Optimization Visualization Factory Framework Process Data Collection Personnel Management Machine Data Collection 1 Shop Floor

ERP Adapter The direct communication of data is based on Factory Framework s seamless connectivity to SAP interfaces (RFC and IDOC), which perform the following tasks: Books entries of all feedback message types in SAP PP and PM modules. Generates wage slips for firm wage, group piece rates, and individual piece work, for both SAP HR and non SAP payroll accounting systems. Books entries of labor time, coming and going, in SAP time management systems. Books entries of quality messages and machine malfunctions in SAP QM. Transfers the machine and work center states online into SAP. Books quantities and selects production order components. Books incoming quantities in accordance with external and internal stock movements and generates production lot identification. Books all account assignment elements from SAP PS and CO with the collected services in Factory Framework. Suggests corrections directly to the Shop Floor Management System. In addition to SAP, Factory Framework works with a variety of ERP plug ins (e.g. Baan ERP, QAD, and others). ERP Adapter Planned Order Production Order and Processing Order Testing Lot Data Details on Materials Details on Production Lots Production Resources Maintenance and Repair Orders F CTORY FR MEWORK Production Feedback Signals Process Messages Service Data Collection Quality Mesages Production Lot Criteria Protocol Production Orders and Yields Maintenance and Repair Messages 2

Basis Basis is the runtime environment for all Factory Framework modules. Basis allows for the administration of system users and the assignment of role based access rights for authorized functions. It can also implement Single Sign-On User Administration through Microsoft Active Directory. Using Basis, administrators can view work shifts established by company planning initiatives or create work shifts based on on-going performance levels. Basis administers all master data, tracking the operation of work centres, personnel, operational states, and instances of production flaws and optimizations. This data can also be transferred with ease to and from the ERP system to Factory Framework. 1 All server functions (modules) are programmed in JAVA (J2EE-compliant) and are supplied with Apache Tomcat as the standard operating system, though other Web servers are available upon request. The data is filed into ORACLE on a Microsoft SQL server. Detailed Scheduling and Control This module gives planners and supervisors the data they need to create ideal work process sequences on-site at the work center. It creates fast and flexible parametric simulation cycles in minutes, processing simultaneous coverage calculations for all available production resources, such as machines, personnel, and production equipment. These cycles are visually displayed within a graphic planning interface, which allows supervisors manual access to sequence planning. The supervisor has access to any archived production period, allowing for quick analysis of the overall workload and revealing potential bottlenecks. This module facilitates the integration of the MRP process with ERP, including safeguarding purchased materials, synchronizing production sequence structures with work processes, planning set-up times and criteria, and scheduling work shifts to align with available production resources. 3

2 3 Order Management This module displays orders from the ERP system to supervisors through the Office Client Interface, and to workers through the Worker Client Interface. Any changes made to the order (such as changes in quantity and status) are visible in the ERP system instantaneously. Workers can view deviations of planned lead times and document them. Workers can also classify and describe instances of product rejection or rework manually. Lots and components can then be signalled with a feedback message by the supervisor. The machine itself can identify malfunctions and interruptions to workflow, which can be further documented by factory staff. Computers are usually equipped with readers for the personnel and/or allocation identification (barcode reader, RFID) to administrate access rights and data collection. The connection of further peripheral devices, such as testing equipment or pallet label printers, is effortless and convenient. This module accounts for a diverse workforce in a multitude of ways: It is easy to use. It secures operations by creating terminal specific configurations. It provides touch-entry assistance to the visual interface. It performs in multiple languages. It can be specified for left or right handed operation. It minimizes faulty data entry using sophisticated, company-specified plausibility checks and by recording all quantifiable production information. Production Data Management Through this module, pertinent files are easy for the work to access using the Worker Client touch screen interface. Using role-specific key terms, workers can search for and administer DNC programs, and open any electronic production files needed at the machine. This data is imported to a document administration system (PLM), which can be manually operated or fully automated. Documents can also be filed in a separate directory in case of emergencies. DNC programs can be transferred to the machine using the Worker Client Interface or input directly using the data management module recall program. Programs tested and modified on the shop floor are easily filtered and compared with original programs using any standard editor, such as CIMCO.

4 5 5 6 SFM Reporting This module takes standard operational state evaluation reports, such as quantities and strokes and ABC analyses, and compiles and analyzes the data. It then compares the actual outcomes of a reporting period to the original processing plans used for the reporting period. These comparative analyses are ongoing, and displayed in real-time during the manufacturing process, allowing for instant adjustment and optimization. All module evaluations support Total Productive Management. TPM Performance Analysis also supports accurate Overall Equipment Effectiveness (OEE) evaluations. Any manufacturing hierarchy can be integrated using this module. The ability to specify favorites allows staff to create custom reports that update analysis data instantly. In addition to preconfigured evaluations, all data charts can easily be recalled by SQL by using an extension module. Both preconfigured reports and data charts can be integrated into the module navigator and be assigned to an individual staff member s administration rights. Alert Management The alerting module promotes process stability, backtracking, and quality data management by collecting test data collection, operational states and measured values cyclically. This data includes state period, state type, temperature, pressure sequence, IO7NIO messages, etc. Alerts will also be displayed directly to workers and supervisors in case of a critical event where data changes dramatically. If test criteria are violated, an alert will be activated. Alert messages can be sent to third parties by text message or email. Visualization The visualization module displays measured values and operational states with a graphic web-based editor. Staff can use the module to configure production shop layouts and establish TPM controlling reports, which can be used as andons on the shop floor. By visualizing the shop floor layout, production plants can be designed or realigned to increase efficiency, based directly on measured values and process analyses. All collected data can be visualized, making data easy to access and understand on all levels of the manufacturing process.

Machine Data Collection 7 8 Process Data Collection This module facilitates direct flow of machine data by connecting digitally to Siemens RPC, OPC, and FANUC. Users can recall data on an automatic cycle or manually recall special data elements in instances of machine deviation. This module then standardizes received data and compares it to operational states using a formula editor. In addition to monitoring machine functions, this module can collect measurements such as temperature, pressure sequence, IO/NIO messages and visualize these events as a sequence in real-time. 9 Factory Framework Machine and Process Data Collection communicates directly with a wide variety of Siemens SPS model series S5 and S7, and standard adapters are available for most machine control types. Using Siemens offers two options for direction connection of a Simatic to the company ethernet: Siemens CP343, Cp443, VIPA CP 143, or lean types of communications processors. Connecting an IBHLink to a MPI interface, or a PG Interface of a Simatic. Other connection options include OpenModbus through TCP/IP or through machine controls with OPC servers. Factory Framework can connect machines by both digital and analogue systems, typically utilizing a WAGO Field Bus Controller. This unit reads signals on an automatic cycle and transfers it to the network interface. This effects intelligent, active data transmissions, so that messages are only sent to the DCU at signal changes. Personnel Management All messages sent through the Worker Client Interface have the option to be personnel related. Personnel feedback messages can be processed as ordinary information, indicating who sent the message. It can also be used to collect personnel time data in the instance of a bonus system or piecework, along with the continuous collection data from processed jobs.