Pi_Inject

MES for the plastics injection moulding industry

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MES for the plastics moulding industry
is a subset of the MES system PiSolutions, designed for applications in the plastic industry. Apart from standard modules from PiSolutions specific functions for the injection moulding process have been added. The interface is defined by the standards Euromap 15 and Euromap 63 (in case of Arburg it is realized through their propietary protocol). The physical connection is via Ethernet. An application has been built that will satisfy the primary needs for the injection moulding plant. The modularity offers a step-by-step expansion of the system, not overstraining the personnel operating a new system. Additional systems like automation, conveyors, robots etc. can be linked to the MES as well and offers the user to survey the whole production floor through a single system.

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MES for the plastic moulding industry
Pi_Inject with its modular design allows growth as the plant grows. Even single modules can be installed if no further functionality is required and employees can be trained step by step if additional modules are integrated at a later stage. The user is then able to overview his production as a whole and to find out about production inefficiencies. The Pi_Inject Bundle contains the following 4 features of PiSolutions: Pi_Perform Pi_Dataset Pi_Excel Pi_Alarm

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Structure

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Pi_Perform System overview

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Pi_Perform Overview
The overview page allows the user to visualize all injection moulding machines. For each unit the machine status, job id, current state of the production and estimated time for end of production are shown. Selecting a unit with the mouse pointer shows additional information such as: number of good parts, number of rejects and more.

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Pi_Perform Machine status
Within the menu it is possible to switch between the overview of status, orders and alarms.

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Pi_Perform Individual machine
Individual Machine Overview Top left: Information about the current job Top right: Status over the last 24 hrs Middle left: Pie chart availability (24h) Middle right: Production per hour (24h) Bottom: Job list with last 6 jobs and running job
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Pi_Perform Cell comparison

The status and quantities menu supports also e.g. a comparison of 2 machines or cells over a defined time

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Pi_Perform Alarm overview

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Pi_Perform OEE Analyser
This screen shows the OEE values for a certain time period. The bar shows the average value over the specified time period. The limits included describe the areas (unsatisfactory, satisfactory, target). The pie chart displays the actual values. The diagram displays the values for availability, performance and quality for each shift as bars. The OEE value is shown as a trend diagram.

PiOEE allows to configure screens according to the customers required information.

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Pi_Perform Real time trends
Process data can be sampled in real time and stored in the data base. This data can then be displayed as trends in real time or historically. Also warning and alarm limits/ranges can be set which will e.g. stop the machine.

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Pi_Perform Process Values

Process values to be visualized are defined before installation and can be accessed through the menu. Also Alarm limits and warning limits can be added and linked to functions like machine stop etc.

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Pi_Perfom Process value comparison

Process values can be selected and compared over a certain period of time

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Pi_Perform Order management

The order tool allows to visualize the active jobs. Also pending jobs and timing of those is shown. If the machine or cell platforms technically allow to swap orders this can be done by drag and drop in the menu.

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Pi_Dataset - Datasethandling
Running a multitude of tools requires a safe and simplified handling of the related machine parameter sets. Pi_InjectTM allows the user to store, versionize and retrieve the data (1) The current data set can anytime be stored in a dedicated file system on the Pi-Server. The transmission must be initiated from the machine. (2) A data set can always be downloaded from the file system to any machine. (3) Additional information can be added to the data set and then stored in the data base. The user can therefore add his comments. A comparison function allows the user to compare different versions of data sets. Differences between the two sets will be highlighted.

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Pi_Dataset - Datasethandling

Active Dataset

Pi_Inject establishes a new version by the time changes are made to the actual dataset

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Pi_Excel - Data in a well-known environment
Process data are a valuable asset and often the need arises to look at data in a way that was not foreseen or not implemented when the MES system was set up. Microsoft Excel is a well known software product from Microsoft and it is an easy way to further process data and to prepare tailor-made reports. Pi_Excel lets the user retrieve raw data from the data base and delivers it to the user in an appropriate Excel format. It is essential to define data base queries that retrieve the information from the SQL data base. These queries can either be defined by bfa solutions ltd or by a competent member of your IT-team. In order to request data the user must: select from a drop-down menu the query that will provide the data needed enter the necessary parameter for this query (e.g. time limits, job number, unit number)

After a short time the values are being fed to his client PC and he can start preparing his special report.
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Pi_Excel - Data in a well-known environment

Process values can be exported to Excel

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Pi_Excel - Data in a well-known environment
from which diagrams and other

graphics can be retrieved.

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Alarmmanagement

A comprehensive management of process alarms is indispensible for an optimal operation of production. Alarms and critical warnings must immediately be brought to the attention of the responsible personnel. This can be handled via SMS and e-mail reports. Help pages should give support to the engineering personal who must react to the situation. After the problem is solved the occurrence must be classified and if necessary corrective actions need to be proposed. It must be possible to distinguish between various priority levels, which will demand various reactions to the problem. An alarm management system must also provide built-in statistical information in order to make troublesome areas recognisable.

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Alarmmanagement
Each event (alarm, warning etc.) can be given a certain priority. The behaviour for each priority level can be configured, as for instance: Various colour schemes, needs acknowledgement, alert via SMS and email (requires Pi_Notify). The Alarm page can be configured individually. Filter functions allow the user to oppress certain alarm groups. This can be used to focus the attention on critical situations or to blank out areas where maintenance work is been carried out. The operating manager (if authorised) can define help information for every alarm and warning. If an alarm with specified help is active the alarm message will alert to this fact. In addition, a link to a further site can be provided within the help information.

The following reports are available: Alarm history: Alarm statistic: Alarm list:
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lists the stored event over a certain time period, filtering can be used groups alarms according to sorting criteria lists all alarms defined under Pi_Alarm and the configuration data

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Pi_Alarm - Alarmmanagement
It is possible to disable certain groups or certain priorities in order to improve clarity for the operator. This will for instance be used if a certain part of the production line is down for maintenance whereas the rest is running.

Bottom: Alarm display showing the current alarms. According to the defined procedures it may be necessary to acknowledge certain alarm classes.

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Pi_Alarm - Alarmmanagement

Selection of characteristic

Selection of machine/system/equipment

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Pi_Alarm - Alarmmanagement

There are many options for the reprocessing of the Alarm data. One will be the report about the chronological history of Alarms.

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Pi_Alarm - Alarmmanagement
Alarm reports help to identify critical parts of the production line and are indispensible information if it comes down to decisions about what to plan in order to increase availability.

The reports can be exported in PDF format.

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Contact details
For further information or questions you are welcome to contact us any time through: www.bfa.ch

or

+41 (0) 44 806 64 64

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