SHOP FLOR MANAGEMENT FactoryFramework. PHASE I: Machine Data Collection, Visualization, and Reporting. Production Award

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1 SHOP FLOR MANAGEMENT FactoryFramework PHASE I: Machine Data Collection, Visualization, and Reporting Production Award

2 SYSTEM BRIEF TRANSPARENCY; Every machine states is recognazible Visualization of Production System Status Root Cause Analysis (Faults, Downtimes,...) Web-based Interface Anywhere / Anytime Access Accurate machine data greater visibility Wastes analysis for continuous improvement Better data: where are the operators working Real-time analysis instead of reactive FORCAM 2013 PAGE 2

3 Shop Floor Management Realtime deviation analysis for EVERY work place ACTUAL TARGET Office Shop Floor Office Shop Floor Shift Shift Manual Time-delayed? Realtime / Online ACTUAL-TARGET Comparison Realtime / Online ACTUAL-TARGET Comparison? ANDON Visualisation Realtime / Online ACTUAL-TARGET Comparison FORCAM 2013 PAGE 3

4 Project overview There are downselected machines that represent group of machines(type of PLC/hardware): MACHINE PLC TYPE TECHNIC TUR Manual machine WAGO TZC 80N Sinumerik 810D IBH LINK Hyundai-KIA SKT- V5 Fanuc 21i-TB FOCAS CTX 410 Sinumerik 840D 31A IBH LINK Mazak megaturn 900M Mazarrol Matrix nexus NC Model FCA730PY-N31 DMC Sinumerik 840D SL RPC MT-Connect Makino Fanuc FS31iB5 FOCAS FORCAM 2013 PAGE 4

5 System architecture NOT in Ph I FORCAM 2013 PAGE 5

6 Machine Data Collection (MDC) with Heterogeneous Adapters SFM Reporting, Analysis & Visualization Machine Data Collection (MDC) for Heterogeneous Controls/PLCs Plugin Siemens TCP/IP native Plugin Siemens RFC 1006 Plugin Modbus over TCP/IP Plugin OPC / OPC-UA Client Ethernet (Works LAN) FANUC Siemens 840D / TI Omron OKUMA Heidenhein MAZAK Plugin MTConnect PLC S5/S7 Mitsubishi Makino Fieldbus Controllers for Legacy Controls (B&R / Elau / G&L / Koyo / Other) Factory Framework connects to and acquires real-time data from various machine controls using a variety of readily-available protocols. FORCAM 2013 PAGE 6

7 PLC vs. hardware Siemens S5/S7- IBH Link FANUC- Focas Wago FORCAM 2013 PAGE 7

8 Machine-Shop Visualisation FORCAM 2013 PAGE 8

9 Machine-Shop Visualisation (3D) FORCAM 2013 PAGE 9

10 Single machines visualization/monitoring FORCAM 2013 PAGE 10

11 Reporting Status Gantt Diagram FORCAM 2013 PAGE 11

12 Reporting Status Log FORCAM 2013 PAGE 12

13 Reporting: Shift Book FORCAM 2013 PAGE 13

14 Reporting : Operational Status Reports FORCAM 2013 PAGE 14

15 Reporting: Maintenance HIT list FORCAM 2013 PAGE 15

16 Rollout No. Line Machine- ID SAP No Machine Text Name of Machine PLC Type Techinic 1 SW MAZAK Tokarka CNC Mazatrol 640T Nexus Mtconnect(do sprawdzenia) 2 SW TZC Tokarka uchwyt. wielonoz. SN Siemens Wago 3 STUDER Szlifierka do walków Wago 4 OFA-1 Frezarka obwiedniowa OFA-16A Wago 5 GLEASON Dlutownica do uzębień CNC Sinumerik TYP?? 6 BUAJ- Szlifierka do walków CNC Fanuc 0 GC Wago 7 BUA-2 Szlifierka klowa Kavalir K 51 Wago 8 MORI Tokarka CNC MSX 850 III Wago 9 MORI Tokarka CNC MSX 850 III Wago 10 SOJ-1 Szlifierka do otworów Wago 11 MAZAK Tokarskie centrum obróbcze - MAZAK Mazatrol matrix 2 Mtconnect(do sprawdzenia) 12 KAPP Szlifierka do uzeb. KAPP CNC Optronic AG CNC D 150/OP 500 Wago 13 OKUMA Tokarka CNC- OKUMA LB35 II Okuma OSP U100L Wago/ Okuma plug in it think protocol 14 - Tokarka CNC- NEF600 Sinumerik 810D NCU Wago 15 TUR Tokarka uniwersalna - TUR-630M Wago 16 EUR Tokarka pociagowa Wago 17 TZC Tokarka uchwyt.wielonoz. Sinumerik 810 D CCU 3.4 IBH Link S7 (jeżeli MPI connector jest dos 18 TZC Tokarka uchwyt.wielonoz.sn Sinumerik 810 GA3 IBH Link S7 (jeżeli MPI connector jest dos 19 AXA Frezarka pionowa SN Heidenhain LE426M Wago 20 TZC Tokarka uchwyt.wielonoz.sn Sinumerik 828D SL IPS7LNK on X 130 Network Connector IP S 21 MAZ Tokarka klowa wielonoz SN Mazatrol Fusion 640 Mtconnect(do sprawdzenia) 22 TZC Tokarka uchwyt.wielonoz.sn Sinumerik 802D SL Wago 23 BOS Frezarka pionowa NC Bostomatic Wago 24 ID Szlifierka do otworów Wago 25 TSCHU Szlifierka do walków CNC Ge Fanuc Series 18 T Wago Szlifierka do otworów AEROTECH Wago 27 STU Szlifierka uniwersalna Wago 28 DMC 125 FD duoblock Centrum obróbcze DMC Sinumerik 840D SL IBH Link S7 / MCIS RPC 29 UCP-800 Frezarka MIKRON Heidenhain itnc Mazak Integrex e-500h II Centrum Frezarsko-Tokarskie Mazatrol matrix 2 Mtconnect(do sprawdzenia) 31 NH4000DCG Frezarka CNC MORI SEIKI Fanuc Series 31i Model A02B 0307 B822 Focas 2 32 Roboform 550 Elektrodrążarka Fanuc Series 180I MB Model A02B 0283 B801 sprawdzić Focas 2 FORCAM 2013 PAGE 16

17 Project Steering Committee FORCAM 2013 PAGE 17

18 Pratt & Whitney (Kalisz, Poland) Phase 1 SFM for Machine data collection, visualization, and reporting. Phase 2 includes SAP ERP integration and dynamic scheduling. Our contact persons that are running the project area: Zbigniew Gralka, P&W Production Director Robert Choja, P&W Production Manager Tomasz Koczorowski, P&W IT/Business Process Optimization Officer FORCAM 2013 PAGE 18

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