Process Quality Manager Monitor and document process data. With ConnectedManufacturing Solutions by Bosch Software Innovations. Software Innovations

Transcription

1 Process Quality Manager Monitor and document process data. With ConnectedManufacturing Solutions by Bosch Software Innovations. Software Innovations

2 2 Process Quality Manager Managing process data the intelligent way Do you have a handle on your process data? Industrial manufacturing companies are constantly faced with the challenge of increasing productivity, reducing rework costs, and achieving rapid production ramp-ups. The cost pressure is intense. Faults in production are expensive they can cost you your competitiveness. You can master these challenges by continuously optimizing your process quality. The Process Quality Manager helps you to detect and avoid faults and deviations as early as possible. An early warning system that cuts error costs! You can monitor and document your production processes securely and reliably with the Process Quality Manager. Should there be any deviations from the target process, you can immediately take preventive steps and avoid producing defective parts. Error reports are quickly sent to the relevant specialists, who can put their expert knowledge to better use. Realizing savings by using the Process Quality Manager: the time needed to respond to an identified deviation can be cut in half. Using the process data cockpit helps specialists identify deviations more quickly and start the analysis without delay. You don t have to worry about reporting the error or gathering the required data the software does that for you. This means a considerable reduction in response times throughout the entire process, from identifying a deviation to resolving it. Ideally, these faster response times should enable you to avoid errors altogether.

3 Process Quality Manager 3 Bosch Rexroth Your process data cockpit: visualizing, analyzing, reporting Using a cockpit, the Process Quality Manager visualizes the various performance indicators and tolerances so that you can identify and resolve problems more quickly. A series of analysis functions help you immediately identify systematic errors, detect trends early, and contain causes so that measures can be taken before a defective product is even made. Numerous reporting functions allow continuous monitoring of the success of the measures. Benefits of the Process Quality Manager at a glance Early detection of process risks: enables preventive measures and avoids failure costs Faster reaction to process errors: reduces failure and reworking costs, results in more output Continuous process transparency: supports continuous improvement and enhances utilization of specialist knowledge New business models for machinery and component manufacturers For machinery and component manufacturers, the Process Quality Manager offers the potential to enter new business areas in order to benefit from the growth engine of a digitized and connected production. Along with machines and components, manufacturers can also offer their customers the process data cockpit as an early warning system. With this all-inclusive, worry-free package, they don t just provide customers with a product, but with a service for continuous improvement as well. Machinery and component manufacturers themselves benefit as well, since their competitive edge increases, their portfolio expands, and their devices are enabled for Industry 4.0.

4 4 Process Quality Manager The Process Quality Manager: In practice: using for safety-critical tightening processes The Process Quality Manager pools the data from safety-critical tightening processes and displays it in an aggregate view the tightening data cockpit to permit continuous monitoring and analysis of the processes. 1 The transparent factory: overview of all tightening processes A plant overview in the cockpit is provided in the form of a tree structure. The various levels make it possible to quickly and easily navigate through plants, areas, lines, stations, tightening applications, and down to individual channels. A status overview for the entire plant uses color changes to indicate the current status of all connected tightening systems. If defined thresholds are reached or exceeded, the color changes to red. Plant overview in the cockpit Creating favorites To maintain an overview, even of a large number of machines, any level can be selected as a favorite in order to monitor specific units and gain faster access. Managing users/roles/rights The tightening cockpit enables the independent management of users, roles, and rights including authentication. Different roles can be defined for users in distributed and heterogeneous teams according to their responsibilities, along with the corresponding views and access rights. 2 Optimizing processes by carefully analyzing tightening processes A variety of views are available to experts for analysis of the tightening process, so that they can quickly identify process changes early on. In addition to the tightening curve, many other types of assessment are available to enable a systematic analysis of the completed tightening and to reveal trends early on. The other assessment types include a field of nine, single value card, probability plot, histogram, and box plot.

5 Process Quality Manager 5 Analysis of the tightening events in a range of views The tightening curve depicts the course of a selected tightening event in a torque angle chart. Selecting a curve section enables users to further zoom in on the tightening curve. Additional data is displayed below the tightening curve: minimum, average, and maximum values, standard deviations, and final torque values and angles. It is also possible to superimpose multiple tightening curves to compare them more directly. In the field of nine view, the final torque and angle values are displayed as points. 3 Reacting quickly to errors thanks to real-time data acquisition Process data is transmitted from the nutrunner control to the tightening software solution in real time, stored in the database, and visualized in the web-based user interface. You can use all common web browsers to access the tightening data cockpit. Users have immediate access to all tightening process data and can intervene if necessary. 100 tightenings displayed changes; additionally the expert in charge is notified. Notification when trends or runs are detected as well as atypical behavior of critical measured values. Night view: darker layout is easier on the eyes during night shifts. Cockpit by night 4 Additional features Broad range of reporting possibilities: users can create, save, and send user-defined reports using a wide variety of search fields. Documentation: the component ID for every completed tightening is stored in the database. This information is of particular relevance in case it is necessary to conduct a careful analysis of a component s tightening afterwards. Notification when certain NOK rates are exceeded: when defined thresholds are reached or exceeded, the color of the plant overview and in the most recent

6 6 Process Quality Manager The Process Quality Manager: Handling large volumes of process data System architecture: Tightening data cockpit Visualization & analyses Web application Office Intranet Firewall Data handling Process database Quality database Demilitarized zone Firewall Manufacturing line Production control Existing Quality Management System Process Data Cockpit The system architecture Every completed tightening generates data that is sent from nutrunner control to data processing, where it is bundled, prepared, and processed. The system can process large volumes of data from multiple tightening systems at a rapid rate. In the final step, the data is stored in a process database. Experts can access the data sets stored in the database using a web browser on their smartphone, tablet, or laptop. An example of a tried-and-true configuration 500 Bosch Rexroth tightening systems (Firmware 2.4) with a cycle time of 10 sec. Two Linux servers Relational database Web-enabled devices

7 Process Quality Manager 7 Bosch: Your partner for connected manufacturing Industry 4.0 Create transparency. Increase productivity. Reduce costs. Software-based system and service platforms, such as well as those provided by Bosch Software Innovations, will play a major role in tomorrow s industrial manufacturing. They enable connectivity and communication between the machines and workpieces in production. production and logistics processes along the entire value chain. For example, quality monitoring of transport units reduces waste and detecting machine faults early on makes it possible to schedule maintenance in advance. Bosch Software Innovations provides producers as well as users in the manufacturing industry with innovative solutions. Our ConnectedManufacturing Solutions for connected production and logistics collect, visualize, and analyse machine, process, and sensor data. They help to translate this data into meaningful information, which in turn provides the basis for deriving rules- and process-based measures. The resulting increase in transparency facilitates a targeted optimization of the For us, Industry 4.0 means developing intelligent, connected solutions that allow you to manage your production and logistics challenges reliably both now and in the future. Put your trust in the many years of experience and the flexible and modular solutions offered by Bosch Software Innovations. The Bosch IoT Suite the technological foundation The Bosch Group years of manufacturing experience The Bosch IoT Suite provides the technological basis for our ConnectedManufacturing Solutions. Thanks to its modular design and flexible components, the IoT platform is ideally suited both for projects in the Internet of Things as well as for enterprise applications implemented using Business Process Management (BPM) and Business Rules Management (BRM). The platform makes it possible for you to efficiently develop innovative and future-ready solutions for new business models. The Bosch Group is one of the world s leading technology companies. Bosch drives Industry 4.0 forward both as a leading user and a leading supplier. For many years, Bosch has offered products and solutions that support machinery and component manufacturers as well as manufacturing companies in all processes along the entire manufacturing value chain. With its broad portfolio, the Bosch Group is represented in all relevant Industry 4.0 product categories: from sensors to hardware and software through to integrated system solutions.

8 Europe Bosch Software Innovations GmbH Schöneberger Ufer Berlin Germany Tel Fax Americas Bosch Software Innovations Corp. 161 N. Clark Street Suite 3550 Chicago, Illinois 60601/USA Tel Fax Asia Bosch Software Innovations c/o Robert Bosch (SEA) Pte Ltd. 11 Bishan Street 21 Singapore Tel Fax Bosch Software Innovations GmbH, the Bosch Group s software and systems house, designs, develops, and operates innovative software and system solutions that help our customers around the world both in the Internet of Things (IoT) and in the traditional enterprise environment. We place particular focus on the topics of mobility, energy, manufacturing, and building. Our IoT platform the Bosch IoT Suite allows the interaction of devices, users, companies and partners on a centralized platform. This enables the development of innovative and future-oriented solutions for new business models. With some 550 associates worldwide, Bosch Software Innovations has locations in Germany (Berlin, Immenstaad, and Stuttgart), Singapore, China (Shanghai), and the United States (Chicago and Palo Alto). More information can be found at The Bosch Group is a leading global supplier of technology and services. It employs roughly 360,000 associates worldwide (as per April 1, 2015). The company generated sales of 49 billion euros in 2014.* Its operations are divided into four business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. The Bosch Group comprises Robert Bosch GmbH and its roughly 440 subsidiary and regional companies in some 60 countries. Including its sales and service partners, Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for further growth. In 2014, Bosch applied for some 4,600 patents worldwide. The Bosch Group s strategic objective is to create solutions for a connected life. Bosch improves quality of life worldwide with products and services that are innovative and spark enthusiasm. In short, Bosch creates technology that is Invented for life. Additional information is available online at *The sales figure disclosed for 2014 does not include the former joint ventures BSH Bosch und Siemens Hausgeräte GmbH (now BSH Hausgeräte GmbH) and ZF Lenksysteme GmbH (now Robert Bosch Automotive Steering GmbH), which have since been taken over completely. 05/2015 RE