MES Use Case: Andon board for production status display

Project target

The customer required to display real-time production information to shopfloor operators, the same data should be available in the production manager's office.

 

Solution

An Andon board (large display) was installed on the production floor, which displays the following real-time production information:

  • Production quantities in the current shift (target, actual, remaining), breakdown by every 30 min
  • Product ID
  • Machine used for the current order
  • Remaining time of order
  • Equipment OEE
  • First Pass Yield
  • Total machine downtime

The same information can be displayed in thin clients on any device via factory LAN, using access rights control.

MES Use Case: OEE dashboards real-time

Project target

Provide real-time OEE (Overal Equipment Effectiveness) information about production equipment.

 

Solution

The applied OEE client application can be opened on any smart device (PC, tablet, etc.) with the correct user rights. The simple dashboards display the following information:

  • Breakdown by Quality, Availability, Performance
  • Current OEE value
  • MTBF, MTBR
  • Detailed downtime analysis, breakdown by root cause categories

 

MES Use Case: Production scheduling application

Project target

Design a flexible and robust production scheduling tool, which enables simpler and faster planning of complex manufacturing processes.

 

Solution

Provided a customized production scheduling application with the following features:

  • Very simple handling by drag-and-drop (eg. pull an operator to a machine to assign him to the current task).
  • Assign the production machines to incoming orders.
  • Assign operators to machines based on their skills, while controlling operator licenses (an operator is allowed to use a machine only if he has the right training or certificate).
  • Synchronization with planned downtimes (maintenance, repair), to ensure the orders are assigned to machines which are available.
MES Use Case: Production reporting

Project target

Need a simple application to provide overview of the current production status, and generate reports.

 

Solution

Provided a fully customized server-client solution:

  • All historical production data is available in thin client application.
  • Credential control for login.
  • Report generation by hour/shift/day/week/month/year.
  • Available data: product type, production time, target/good/reject quantities, downtime, First Pass Yield, OEE.
  • Export to Excel option.
MES Use Case: Scrap reports

Project target

Collect all scrap-related data into a common platform, enabling detailed analysis and reporting.

 

Solution

Some of the features of the final solution:

  • Manual (with tablet placed at the machine) or automatic scrap data collection.
  • Breakdown categories by machine, operator, shift, root cause, etc.
  • Simple customizable graph displays, Pareto reports.
  • Scrap rates based on total production quantity.
MES Use Case: Machine downtime management

Project target

Define a common platform for handling machine downtimes, including root cause registration, maintenance ticket issuing, downtime recording.

 

Solution

Provided a tablet-based application, used by production floor operators. Some features of the solution:

  • All production machines are connected to the system.
  • If a machine is down, the operator has to acknowledge (with credential control) and select the root cause (lack of material, breakdown, quality issue, etc.), which is assigned to the machine. Different root causes are displayed with different colors.
  • After acknowledging, a service ticket is issued automatically and submitted to the maintenance staff.
  • The system records: acknowledging person, reaction time, repair time.
SCADA Use Case: Central data collection

Project target

In the plant of a global pharmaceutical company there are numerous isolated SCADA systems operated, these need to be connected and all the data need to be available in a central SCADA system.

 

Solution

Installed a central SCADA system using iFIX, with the following features:

  • The legacy SCADA subsystems are connected in star-topology to the new central SCADA.
  • Data tag sources: field PLCs and PACs (Programmable Automation Controller).
  • The field devices communicate with a central KepServerEx OPC server (in mirrored architecture for redundancy).
  • All historical data is stored in a Historian database.
SCADA Use Case: Climatic chamber monitoring

Project target

In the factory of KUKA Robotics Hungary all robot control modules undergo an aging test in special climate chambers: during dynamic temperature changes the control modules are turned on-off frequently, meanwhile the motherboard data is saved. The target was to develop a system, that displays the real-time status of the control PC-s, and initiate alarms in case of errors.

 

Solution

Installed a monitoring SCADA system using iFIX, with the following features:

  • Monitoring of various signals (power supply presence, temperature, door on/off, etc.).
  • Applied a web based client, can be accessed remotely outside the climatic chamber.
  • In case of anomalies in the chamber conditions automatic alarms are submitted via SMS/email.
  • Every time the testing starts/stops, the responsible persons are automatically notified.
SCADA Use Case: Freezer room monitoring in food factory

Project target

The customer maufactures fast-freeze food products, its facility has several freezer rooms. The task was to setup a new SCADA system to monitor the conditions of these rooms.

 

Solution

Installed a monitoring SCADA system using iFIX, with the following features:

  • The system is operated in 24/7.
  • New HMI screens were setup using Omron NS.
  • Operators can manipulate the freezer room devices (evaporating condensers, oil system, etc.) on the HMI.
  • Data sources: Omron PLC-s and Schneider Electric power meters.
  • All data are stored on data collection servers, using Historian and MS SQL.
  • In case of threshold overrides automatic alarms are generated and escalated to the responsible persons.
SCADA Use Case: Central monitoring system for pharmaceuticals

Project target

The customer is a global manufacturer of pharmaceuticals, requested to setup a central monitoring system (CMS) for their entire facility.

 

Solution

Installed a CMS SCADA solution using iFIX, with the following features:

  • Fully centralized data collection and visualization.
  • Monitoring of various machinery (isolators, filling machines, solvent system, etc.).
  • Receipt-based process control: receipts are stored in the SCADA till process start, then these are downloaded into the control PLCs.
  • Electronic report generation about the sterilization process.
  • The system complies with 21 CFR Part 11 and EU GMP Annex 11 directives: user access handling, electronic signatures, Audit Trail, etc.