gimm Global Integrated Manufacturing Manager. Solution for industrial management of productive and logistic factory processes

Transcription

1 gimm Global Integrated Manufacturing Manager. Solution for industrial management of productive and logistic factory processes

2 Solution for industrial management of productive and logistic factory processes gimm is a modular package solution that allows the management of a company's productive and logistic activities using modern technologies and guaranteeing appropriate service level with reduced material and product inventories. The use of gimm solution allows triggering the on-line execution of activities and processes that requires the high automation level of a company and a strong coordination and collaboration with their customers and suppliers.

3 gimm solution is an ideal system group applications for the following processes Management of deliveries from a company's productive plants, synchronizing them with their customer plants/ suppliers so that they can operate using modern logistic technologies such as Just-in Sequence (JIS) or Batch Lot-size ("Kanban ). Management of a factory's internal production through automatization of their productive operations in Manufacturing Execution System" (MES) modality, controlling the robots at workstations or work cells and thus guaranteeing follow-up and automatic traceability of both their productive processes and finished products. Management of a company's logistic chains and flows based on real demand (B2O- Build-to-Order), controlling reception andstorage of the components delivered by suppliers, the internal preparation handling operations of material as well as the storage and shipment of finished products delivered to their customers.

4 Functional Module LINCS Sequenced preparation and supply management The "Just-in-Sequence" (JIS) methods need a Linkage Control System (LINCS) between the supplier s and the customers. This module allows validating and sequencing processes of the products delivered to the customers, avoiding preparation errors and guaranteeing correct fulfillment of the customer orders in material type, delivered quantity, delivery sequence, unloading point and time of delivery. It consists of: Special integrated EDI functions for the exchange of external files referred to this business (receive and send) processed in standard formats such as DELJIT, VDA, XML, ODETTE, etc. or in proprietary formats. Data transcoding of received messages into internal company references. Management of sequenced components according to received orders, allowing synchronized identification of each component with the customers own production. Management of sequenced packages by generating various types of packages, according to the sequenced components they should contain. Package grouping and closing at truck level. Printing and reprinting of labels for parts and packages. Shipment validation to control and guarantee the shipment service of the packages via barcode scanning (parts and/or package labels). JIS warnings provided by a monitoring function which detects incidents such as delayed receiving of customer order messages or possible skipped or lost sequences.

5 Functional Module PROCS Traceability and production control Integration The "Production Control System" (PROCS) inside of the MES concept (Manufacturing Execution System) is intended for the vertical systems integration allowing to establish the communication between the corporative information systems and the workshop level equipments, like PLC's, screwing machines, sensors, transelevators, artificial vision, scanners, light signals, touch-screens... PROCS performs a follow-up of the product during its production process, capturing data during the checking processes (traceability) and taking actions as well as making decisions in the production line control (operational supervision). The operational supervision allows the definition of different workstations as well as decision-making in the production control at part level and workstation level. The system can be configured with remote clients which inform and interact on the operations in progress in the productive process. Some examples of operational workstations would be: Poka-Yoke stations ("error proofing"). Pick-To-Light stations. Re-processes (error elimination). Processes defined by the client (unitary checks, time control between operations )

6 Functional Module PROCS The control algorithms defined trough the workstations permits managing the different critical points of the assembled parts and the complete control of the production process. Traceability is achieved by gathering multiple data of the productive process, such as presses, sensors, process times and in general any captured data from an element of the plant-shop. Traceability is completed with the storage of the captured data in a structured way in the PROCS database and further used in graphs and reports that are configured according to customer needs (KPIs). Physical interconnectable devices are: Atlas Copco Screw driver. Drilco Screw driver. PLC Siemens Sematic S7 with protocols: TCP/IP, ISO on TCP and MPI. Serial port connections, for different devices and sensors. TCP/IP Scanners. Beckhoff IO Systems using common protocols (profibus, interbus, ethernet, ethercat, devicenet...) PROCS can be interconnected, even on different machines, any topology can be supported using OPC as brige. Additionally, it allows internal auto-generation of production orders to manufacture spare parts, to maintain safety stock, etc.

7 Functional Module STOCS Logistic flow management The "Storage Control System" process (STOCS) offers the management and the maintenance of logistic operations that flow in terms of storage and preparation of components and finished products. It supports configurations by customers in multi-plant and multi-warehouse layouts. This module provides the following functions: Warehouse map management, racks, stacking, areas, blocks, etc. Storage control, from fixed to full-chaotic storage of material and packages at the location, and item level according to their physical and operationalcharacteristics and based on the availability of space in preconfigured warehouse areas. Control of supplier pick-up from supplier loading orders and waybills. Incoming goods management from external suppliers as well as internally manufactured or assembled finished products. Management of regular internal warehouse operations (pickings, groupings, location changes, regularizations, inventories, etc.)

8 Functional Module STOCS Management of commissioning operations including the following functions: Generation of pre-picking orders for deliveries and production. Generation of picking orders to extract material from the warehouse for deliveries to customers or production issues. Final customer delivery operations are facilitated by delivery notes, and packing list management by carry and customer / dock unloading. The interfaces with the ERP corporative systems of the company are normally included into the solution. There is a complete integration with JIS to control the extraction of sequenced deliveries and with PROCS to control the issuing of components to production areas and the deliveries of finished products to the customers. Stock and historical queries in all situations and statuses. The warehouse processes are performed in real time via mobile and static or fixed terminals with radiofrequency and barcode scanners.

9 The gimm Core To unify and to simplify the common processes, the core system provides a group of modules shared for all functional systems. Printer manager: Provides printing capabilities and the generation of excel reports. Language manager: Set of translation methods. Configuration manager: Manages the configuration and the operative parameters. Session manager: Controls who is accessing to the the system, and access's characteristics. Archiving manager: Database maintenance tasks. Purge and export data. Interface manager: Handles interfaces to and from external systems. Hardware manager: Centralizes the communication with external hardware devices. Framework: Operational and modular agent queue. It has a set of Modular Functional Units (MFU) to configure an algorithmic process. Data Security: Database replication management tasks ( twin system ). Web browser based client:: It is a generic user GUI, browser-type, which gives access to the system. It is user configurable and multilanguage. Logging and tracing: Unification of the registration methods for warnings and errors The gimm Tools A group of utilities, supplied with the system, that help in system management and administration tasks. Services core configuration, manage the general parameters of the core services. Report preview, shows a report result. Administration console, it is a user's interface that shows the state of the different services of the system, logger of the system,.

10 TECHNICAL CHARACTERISTICS Designed in.net architecture with C# and Win32 with C++ using XML and ASP methodologies to operate on windows and Oracle and/or SQL Server databases. It supports communications in nets ISDN, VPN, Frame Relay, X25... with any protocol (TCP/IP, OFTP, ftp, LU ) Supported network communications: ISDN, VPN, Frame Relay, X25, etc. with any protocol (TCP/IP, OFTP, ftp, LU-6.2, etc.). Processing of standardized messages (VDA, EDIFACT, Odette, ANSI, etc.) as well as proprietary messages in any format. Open and configurable architecture with simple, robust and cost-saving infrastructure. Operational reliability with high availability and performance for highly critical environments. REFERENCES gimm solution is it operating in more than 200 production plants located int Europe, Asia and Americas that are running their production and deliveries with their customers. The gimm solution is currently operating in supplies for various automotive manufacturing plants such as: AUDI, BMW, CITROEN, DAIMLER CHRYSLER, FORD, GM, JAGUAR, LAND ROVER, MERCEDES BENZ, NISSAN, PEUGEOT, RENAULT, SEAT, SKODA, SAMSUNG, TOYOTA, VOLKSWAGEN and VOLVO. PRODUCT CONTACT INFORMATION Jose Antonio Casado Llorente (gimm) Phone: Mobile: [email protected] Jose Luis Diaz Cerviño (MES & gimm) Mobile: [email protected]