PlantMaster

Manufacturing Execution System (MES)

PlantMaster is a leading MES system for discrete manufacturing. PlantMaster monitors and
synchronizes manufacturing activities from independent operations to globally distributed plants. PlantMaster is designed to seamlessly integrate with the companys ERP system. Using the Microsoft Windows operating system and Oracle database, PlantMaster offers a collaborative suite of application modules. PlantMaster meets the needs of specific manufacturing environments such as plastic processing, engineering and assembly operations. The result is a powerful and flexible management tool providing managers with real-time visibility on all Key Performance Indicators (KPI), enabling them to achieve operational excellence and rapidly respond to changing conditions.

PlantMaster client-server concept: Wireless monitoring

Ethernet/Euromap 63

Injection molding
Planning Windows Server

DU8P HSDL M-Server

Blow molding Scale

Ethernet

Monitoring/Reporting

Ethernet

DU8P/WDL
Extrusion
Traceability

WDL-Server

DU8P/WDL
Metal stamping
Statistical Process & Quality Control

TSDU/WDL
Host

Assembly

Software modules
Real time monitoring
Cycle time monitoring Downtime and scrap analysis Key performance indicators (OEE)

Connecting remote sites

PlantMaster supports the connection of multiple plants to one
central server. In the remote site, M-servers or WDl-servers, connected to a leased telephone line or the companys Intranet, link the machines to the central computer system. A dedicated multi-site consolidation module on the central PlantMaster server allows integrated reporting for all sites into one single reporting environment.

Planning and scheduling

Multi resource scheduling Kan Ban Ticket printing

Quality control
Process and product parameters Variables and attributes Control charts & alarms

ERP system integration

PlantMaster is easily integrated with the customers ERP system. Through a standard interface, order and product data is transferred from the ERP system and imported in the PlantMaster database. The integrated export functionality allows a straightforward upload of production data, calculated production schedules, work-in-progress and performance indicators from PlantMaster to the ERP system.

Traceability
Automotive, cosmetic, Per single product or lot User friendly reporting

Machine and mold maintenance

Based on real production

Operator planning and tracking

PlantMaster uses the standard TCP/IP protocols for integration

with the host computer.

Connecting machines to PlantMaster

Wired or wireless network!
PlantMaster supports both cabled and wireless networks to
connect the machines to the central server. Machines are equipped with one of BarcoVisions Data Units for automatic as well as manual data collection or linked directly to the server through their Ethernet interface. The latest generation of production machines are often equipped with an Ethernet interface for host communication. These machines are connected by means of a standard Ethernet network (UTP5 cable or wireless). OPC as well as Euromap 63 are supported as communication protocols. All Data Units can be extended with barcode scanners, RFID tags and label printers.

DU8P: user friendly machine interface unit

The DU8P is BarcoVisions standard data collection terminal. This Data Unit automatically counts production, monitors cycle times or speeds, detects machine stops and allows operators to enter additional information. Two serial interfaces allow direct connection to the machines microprocessor and measurement devices. Nine user definable quick entry keys are available for fast entry of the most important stop reasons. All other data entry is conducted through software driven function keys. A large and configurable display allows the operator to view all production and planning information at the machine.

Data security
All Data Units can be extended with a module for backup & recovery, allowing a minimum of 24 hours local data storage in case of server or network breakdown.

TSDU: Touch Screen Data Unit

The TSDU is BarcoVisions high end data collection terminal. This unit comes with a 6.4 color touch screen. The TSDU serves as both a traditional monitoring Data Unit and an information point for the operator. Documents in Word or PDF-format are easily transmitted from the server and visualized on the TSDUs screen. Using touch screen buttons, the operator can ask for information related to quality control, process instructions, machine set up, etc. The need for printed documentation is reduced thus taking a big step forward towards paperless production.

Production visibility and analysis

Real time machine monitoring
PlantMasters most important real time analysis tool
is the PlantView. In this color-coded layout of the plant, the machines are displayed in a number of colors, each color indicating a certain machine status or alarm condition. The user selects the type of information to be displayed and user definable filter sets display only these machines which match a certain condition, for example all machines with OEE below 85%, machines producing too much scrap, A mouse click on a specific machine or group of machines opens a window with detailed information for the selected machines.

Reporting
All data is stored in an Oracle relational database. By means of a powerful report and formula generator, users can define and configure their own calculations and reports. Integrated graphics allow managers to build their own personalized dashboards for a quick and transparent analysis and evaluation of all Key Performance Indicators (KPI). With the multi-site consolidation module, managers can compare KPIs and processes between sites, allowing operations to learn and optimize from the best performers.

Auto flagging & messaging

The auto flagging software continuously compares selected parameters or KPIs with pre-defined exception limits. As soon as an alarm condition is detected, this module triggers one or more actions: an e-mail message is sent to selected people or the alarm is transmitted to the machine, where a lamp can be activated and a message for the operator is displayed on the Data Unit screen.
Windows server
2

Data collection

- Cycle time - Efficiency - Process parameters - Stop rate - Scrap level

1

DU8P

Analyze software
3

Compare to standards Auto Flagging

Activate lamp tree Message on DU screen

Mail messaging

Managing job schedules

Real time job schedule
PlantMasters planboard lets you know within seconds whether
you can meet customers requested delivery dates. Orders can be entered directly into the system or down loaded from the ERP system. Based on the actual situation in the plant and technical restrictions stored in the systems database, the system helps the planner in finding the optimum job sequence. Jobs can be rescheduled by simple drag and drop operations on the plan board. Jobs which are too late are automatically highlighted allowing the planner to take the necessary actions to get the situation under control again.

Kan Ban support

More and more automotive suppliers have switched from traditional order based planning (push) to Kan Ban planning (pull). PlantMaster supports this Kan Ban functionality. In the Kan Ban philosophy, material or component need is triggered by the process that consumes this component. A Kan Ban Card is sent to the work center that produces this component. This bar coded card contains the product code, tool and quantity required. Scanning this card at the machine automatically generates a production job in the PlantMaster database.

Planning reports
Once the jobs are scheduled, a set of reports is available for planning, production and set up crew. They allow the managers to organize the necessary raw materials, operators and other resources. Based on the scheduled machine load and the production calendar, the system also generates the tool and color change forecast reports, allowing efficient planning of the changeovers.

Tool configurator
PlantMaster offers a flexible tool to configure and monitor
tools using tool frames and inserts. Based on the order mix and the availability of frames and inserts, the planner can configure family tools on the spot and assign them to one or more orders. The system automatically keeps track of the use of frames and inserts and stores a history of produced cycles for any insert.

Tracing from raw material to finished product

Integrating traceability with monitoring
Product traceability has never been more important than today. Originally, traceability requirements were restricted to security parts in the automotive industry, but now it has become an obligation in various other domains like pharmaceuticals, food, cosmetics, medical devices, etc. The traceability module within the PlantMaster system uses the hardware already in place for monitoring purposes. The Data Units at the work centers are extended with barcode scanners to allow identification of operators, raw materials and components. This significantly reduces administrative work and customer complaints due to wrong deliveries, wrong codification, etc. The system supports electronic signatures as required by 21CFR11 compliance and can be utilized in a FDA regulated environment.

Process routing
In the process routing module, the user defines a routing for each product, containing all necessary production steps. For each step in the process, the machine or workstation is defined as well as all data to be collected. Typical traceability data includes operators, lot numbers, component numbers and process and quality parameters. This allows the system to check in real time if indeed all data is collected during production. The traceability system will automatically generate alarms (activate a lamp for example) in case certain data is forgotten or is falsely entered.

Traceability reports
A powerful reporting module offers reports for forward and backward tracking per product, component and raw material and the search for causes in case of customer complaints. For each individual product shipped, the system stores and reports raw materials and components used in each production step, process parameters, results of quality checks and operators that manufactured the product. Information can be retrieved for as long as ten years in the past.

Statistical Process Control (SPC/SQC)

Quality monitoring...
The PlantMaster SPC/SQC module keeps your process within the specifications required for optimum product quality and generates the documentation your customers demand for their quality assurance programs. For every product, the user defines the quality and process control plan including the parameters to be monitored, the sampling strategy as well as calculations to be used. This way, the user configures the SPC/SQC package to fit his needs. A link with the PlantMaster scheduling software assures an automatic generation of inspection orders at the start of the production order. Production orders for which the quality checks are over due are automatically highlighted by the system.

... in real time

The system samples and stores process parameters as well as part related data and attributes. Process parameters are collected automatically using the Data Units at the machines (serial interface with the machine microprocessor or analog inputs) while part related information is sampled directly from measurement devices such as scales and calipers or entered manually through a PC connected to the system. A special SPC/SQC touch screen terminal is available for convenient entry of sample data on the production floor. SPC/SQC alarms are automatically solved in the production (cfr: auto flagging).

SPC/SQC reporting and quality certificates

The PlantMaster SPC/SQC software offers an extensive set of SPC/SQC reporting tools: control charts for variables and attributes, normality testing, histograms and process capability calculations. For variables, the user can choose between X-R and X-S charts. P, NP as well as pareto charts are available for attributes. The software automatically calculates alarm and warning limits. The system is set up in such a way that the user himself can define how the calculations need to be done (FORD Q101, DGQ), which SPC/SQC rules need to be applied (check for trends, runs, etc.) and which type of control charts should be made. These settings can be modified for every single product. An integrated editor allows the user to generate quality certificates at the end of each production run.

References

Other optional modules

Preventive maintenance
Based on the run time monitored by the system and the maintenance interval defined for each tool and machine, the preventive maintenance module generates a maintenance schedule on weekly or daily basis.

McKechnie

Operator tracking
Direct as well as indirect operators can log on and log off at the machine Data Unit. The operator tracking software stores all recorded information by operator code. As such, reports can be generated showing production, down time, scrap counts, efficiencies, etc. by the operator.

Typical PlantMaster installations

Plastic molding Plastic extrusion

System requirements
Operating systems: Windows 2000 or 2003 for server applications. Windows 2000, 2003, XP Professional, Vista Business, Vista Enterprise or Vista Ultimate for clients. Windows TSE or Citrix for remote connections. Database: Oracle 8.1.7, 9.2.0 or 10.2.0.

Engineering Pharmaceuticals

www.visionbms.com
A00558 03 EN 28/05/2009 DPD

Vlamingstraat 16 8560 Wevelgem Belgium Tel. +32 56 262 611 Fax +32 56 262 690 sales.bv@visionbms.com

BMS bvba

BMS Vision Ltd

Capricorn Park, Blakewater Road Blackburn, Lancashire, BB1 5QR United Kingdom Tel. +44 1254 662 244 Fax +44 1254 267 100 sales.bla@visionbms.com

BMSVision LLC

4420 Taggart Creek Road, Suite 101 Charlotte, North Carolina 28208 United States Tel. +1 704 392 9371 Fax +1 704 399 5588 sales@visionbmsusa.com

Belgian Monitoring Systems is a member of the Itema group. www.itemagroup.com

BMS