Intelligent Software Solutions for Production Planning, Automation and Logistics

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1 Center of Excellence for Smart Production Intelligent Software Solutions for Production Planning, Automation and Logistics Project Management and Resource Planning itwo PPS Production Scheduling and -Logistics itwo MES Machine- and Plant Control, Robot Integration itwo ICS Stockyard Automation itwo SCE Simulation and Visualization

2 RIB SAA System Analysis and Automation Intelligent Software Solutions for the Precast Concrete Industry PLANNING PALLET OPTIMIZATION The complete integration of prefabrication by itwo PPS and itwo MES sets the benchmark in prefab plants. A prefab order is either generated within a construction project in an ERP system (e.g. itwo 5D) or directly inside itwo PPS in the prefab plant. Step by step model data (BIM) is completed and material purchase orders are placed until production release is achieved. Now data is transferred to the production master computer (itwo MES) where detailed scheduling takes place subsequently. The central task of work preparation is the pallet nesting: by means of an optimization algorithm the elements, which are organized in delivery units and sequenced by time, are placed on the production pallets. The warehouse and delivery organisation is taken into account. Likewise the allocation of long beds, stationary tables or special formwork is performed basis for generating data to use a plotter or laser projection. FORMWORK Intelligent control solutions (ICS) by RIB SAA are optimizing motion. A consistent and userfriendly concept characterizes RIB SAA control solutions. Powerful industrial PCs integrate PLC-functions with Windowsbased visualization. Using field bus systems, drives and sensors are integrated decentralized. REINFORCEMENT & CASTING Wire straightening and cutting machines, mesh welding plants as well as truss girder systems are supplied with customized data and the master computer organizes the transport to the pallet on time. We deliver the appropriate control system for the modernization of nearly every brand of such machines. Our algorithms for optimal casting of concrete are based on long term experiences. If recesses, edges or chamfers the automatic casting control provides solutions for any geometric type even for solid and sandwich panels. The master computer has already ordered the right amount of concrete in the required quality in advance at the batching control. Whether shuttering-robot, laser projection or plotter there is the optimal automation solution for every plant. The RIB SAA Multi-Function-Shuttering-Robotic Control (MFSR) supports all well known shuttering systems. Optimal combinations are calculated, the shutterings placed without gaps and the magnets activated. With exchangeable tools, extension formwork of wood or polystyrene are placed, magnets for mounting parts positioned and the area to be casted later is oiled.

3 PPS Workflow control and resource planning MES Work preparation and production logistics PRODUCTION SCHEDULING PRODUCTION CONTROL Increasingly complex production processes are controlled automatically as they are not manageable by the operators: The master computer administrates different pallet types und their temporarily or permanent mounted formwork. By means of a working plan concept the product type defines the production workflow of each pallet. The operator can add or change tasks and working steps at will to adapt the plant logistics to his experiences. By an information system consisting of order-list, production-sequence and demoulding-list, as well as the updated station allocation in the plant, the production manager always has an on-going overview in the plant and is able to adapt the priority of production orders according to delivery constraints. The status is reported to the ERP-system periodically. INSULATION HARDENING Thermic insulated wall systems require new solutions for rationalisation with double- and sandwich wall-elements. The insulation boards (polystyrene) are automatically cut, drilled, placed on the pallet using an articulated robot and the connection bars are set a manually time consuming process which is efficiently automated in this way. Whether rack feeder, friction wheel transports or cross travel cars: all transport units in a pallet carousel are part of a highly reliable plant control system. Automatic transport is generated by the master computer, which is executed by the PLC safely and rapidly. The complete supervision and maintenance is done by using our graphical visualization at distinct operation panels and mobile on a smartphone flexible, modular, failsafe. The heart of the production of double wall panels is the turning device. Depending on the plant type the pallet with the first shell is interlocked or the elements are positioned on suction units and then turned into the freshly casted second shell.

4 ICS Smart control for individual production SCE Stockyard automation VISUALIZATION The integrated, graphical machine visualization gives the operators a detailed view into the control of the machine, even on a tablet or smartphone. Using automatically printed element-labels, pallet and element drawings, the operators are informed online about current production orders and priorities. Product identification and traceability can be managed by barcode-labels or RFID. STATISTICS After demoulding and removing the panels from the pallet, they leave the production environment and commissioning for storage and transport have to be performed. Within the itwo PPS all product data are taken over automatically from the master computer and the following processes are supported optimally. The production manager sums up the performance of the production crew using reports or has this done automatically by the master computer via . Besides product data also process data for optimizing the plant and performance benchmarks are presented clearly. FINISH Facade coverings using tiles, clinker, glass or even photovoltaic elements are regional essential and are gaining increasing importance. We have automated feeding, cutting and placing the parts on the pallet based on a robot, which discharges joint compound before that works as seal, absorption and position fixation of the elements for casting and compacting. DEMOULDING & STORAGE Whether a simple run off truck to a fully automatic rack storage solution, storage operations are also controlled automatically. A reliable measurement of the handled packages is a precondition for a safe operation of rack operators. By means of integrated pre-commissioning algorithms a rapid and efficient truck loading is guaranteed. Finally the de-shuttering robot removes the shutterings from the pallet and feeds them to the shuttering transport and cleaning unit. After the pallet has been automatically cleaned a new production cycle can start.

5 Center of Excellence for Smart Production The RIB SAA Range of Services Engineering Together with our customers we analyze business processes on the one hand and the ITenvironment on the other hand. This enables us to develop optimum integration of our model-based solution platform itwo 4.0 for project management, production and logistics while taking advantage of useful data links to complementary applications. Consulting Defined processes are represented in the software platform, implemented in the client version, trained and tested during go-live and optimized together with key-users. Project Management & Implementation Optimum functioning of the plant and equipment can only be achieved in close cooperation with the plant planners on the one hand and machine and plant construction companies on the other. Our experienced project managers create a detailed process sequence specification, coordinate the cooperation between the various parties involved and therefore guarantee perfect implementation for the customer. International Service & Support In modern production plant where availability is essential, maintenance and service of the automatic equipment is an extremely high priority. Our expert staff analyse the error situation together with the customer. With the help of the remote service access, which is an obligatory part of the installation, almost all errors can be located and corrected immediately. With our PREMIUM HOTLINE we are ready to help you as required 24 hours a day, every day, and we deal with your concerns as a matter of urgency.

6 RIB SAA Software Engineering GmbH Gudrunstraße 184/ Vienna/Austria office@saa.at