ARBURG host computer system (ALS)

Focus ARBURG host computer system (ALS) Active information for efficient production www.arburg.com

At a glance 1 2 Practical production management: Starting with the simple connection of I/O modules, the modular ALS offers all options for an efficient production organisation. Immediate reliable information: retrieve key figures anywhere and on any end devices. With the ARBURG host computer system (ALS), you have at your disposal a standard-setting high-performance, modular fine-planning tool for your injection moulding production. Tried and proven in practice, this Manufacturing Execution System (MES) provides all the features required in a modern, efficient and cost-effective production organisation. With hundreds of systems already installed, ARBURG has a wealth of experience. This experience flows into the continuous advancement of ALS on an ongoing basis. Here also, Made by ARBURG Made in Germany stands for quality and our familiar futureproof technology. 1 Practical production management ALS is the central tool for the reliable and cost-effective organisation of your injection moulding production. The possibilities for integrating your machine fleet are virtually unlimited: from the simple connection with I/O modules via standardised interfaces for all makes of injection moulding machine through to the host computer interface for ALLROUNDERs. A wide range of modules (overview on the next page) which can be combined as required allow you to perform each individual task with ease. Because your chosen configuration can be expanded at any time, you can be confident of meeting future demands. 2 Immediate reliable information An efficient information management system continuously provides you with current online information on your production centrally and worldwide. Feedback and key figures relating to machines, ongoing orders, shifts and production quality are continuously available. This means maximum transparency, wherever, whenever and however you need it: on PC workstations, info screens in production or on smartphones and tablets. This active information therefore permits you to analyse and make decisions at all times. Set-up operations, as well as mould and machine maintenance can be optimally performed. This is also supported by the central management of all setting data. 2 www.arburg.com 09/2014

3 4 5 Fine lannin timum utilisati n a ailable es u es Automatic archiving: effortless, reliable documentati n Easy implementation: rapid system introduction t u essi nal su t 3 Fine planning e i e ula ities in e ti n m uldin duction, such as machines of different capacities or defective cavities, make reliable detailed planning too complex for conventi nal nt l stati ns u need ALS to enable you to complete such tas s inte a ti ely n t e basis nline data, you can optimise batch running times, reduce start-up processes and also set-up times and downtimes when changing orde s i e ma ine a a ity utilisati n coupled with higher production and produ t uality en an es deli e y eliability u use an e fi ient and st e e ti e du tion organisation with which you achieve si nifi ant time and st sa in s 4 Automatic archiving With ALS, you can dispense with the timeconsuming manual recording of your ma- ine and e atin data nt y e s a e t e e e eliably e ented n additi n t highly reliable information, you have more time for other value-adding activities such as du ti n lannin el s y u identify potential for improvement and a y ut ta eted timisati ns n additi nal benefit t e ntinu us and l n term documentation makes audits and e tifi ati ns substantially easie Business example: Injection moulding production with 20 machines 5 Simple implementation We offer you individual consulting to help you devise the ALS system solution to meet y u needs nstallati n and su t du in the on-site implementation through to the comprehensive training of your employees and administrators are provided as a matter u se is is t e nly ay t a ie e a simple, trouble-free system implementation, immediately ensuring high acceptance in the company along with the required added alue is means t at y u in estment ays off from the start and yields the fastest possible etu n Production time Working time 15 minutes of data acquisition per machine/day Manual recording not required 3 minutes less downtime time per machine/day Faults immediately identifiable 6 minutes shorter set-up time per order Online transmission of data records Savings potential per year for 250 working days and 10 set-up operations per day 250 h 250 h 500 h 1,250 h 250 h 1,500 h 09/2014 www.arburg.com 3

Groupwa 610/13 At a glance Practical production management: The individual modules of the ALS can be freely combined and eliminate the need for separate programs e.g. for maintenance. Maintenance 610/11 Information centre 003/10 Base ALS database, machine and operating data recording, production overview, mould management 613/01, 613/05 Clients for PC workstations and laptops, etc. 610/20, 610/21 Mobile ALS for handheld units and smartphones 613/20, 613/21 Terminal for order messages or mould provision 610/22 Info for individual info screens in production 611/08 Web I/O condition Recording of ambient conditions 611/09 Web I/O alarms Output devices for central alarm signalling 612/xx Machine interfaces Drivers for different manufacturers of injection moulding machines and logs 611/1x ALLROUNDER interfaces Connection of ALLROUNDERs as from year of construction 1984 612/21 Device Connector Data recording of systems via network 611/0x I/O modules Connection of any machines and workstations via signals Documentation/archiving 610/01 Reports Order, item and machine-based evaluations, data export 610/19 Events Long-term archiving of event data (alarms, downtimes, etc.) in separate database 610/08 Progression Display of events such as machine status, shift change and cavity change in chronological sequence 610/15 Production log Permanent archiving of process parameters 610/10 Set-up log Daily back-up of SELOGICA set-up log 610/12 Documents Linking of documents with orders, programs, maintenance and much more. I/O-Modules 611/0x Documents 610/12 Device Connector 612/21 Set-up log 610/10 Production/resource management 610/03 Orders Order planning, graphic planning chart, schedule monitoring 610/05 ERP interface Linking with PPS/ERP, adoption of orders, ongoing feedback 610/18 HYDRA interface Data exchange with HYDRA (MPDV) 610/16 Production variants Material planning of alternative moulds, taking account of performance of machines ALLRO interfaces 611/1x 4 www.arburg.com 09/2014

Resource conflict 610/17 Production variants 610/16 MES interface 610/18 Batch 610/23 ERP Interface 610/05 Orders 610/03 re Base 003/10 Programs 610/02 Programs plus 610/09 Quality 610/04 Clients 613/01, 613/05 Reports 610/01 Mobile 610/20, 610/21 Production log 610/15 Events 610/19 Terminal 613/20, 613/21 Progression 610/08 Info 610/22 Web-I/O condition 611/08 UNDER Machine interfaces 612/xx 610/17 Resource conflict Monitoring of moulds for double assignment 610/23 Batch Documentation of batch changes in order logging Web-I/O alarms 611/09 610/13 Groupware E-mail or SMS in the event of faults or maintenance, cyclical reports 610/11 Maintenance Maintenance plans, monitoring, due dates, documentation Quality assurance 610/02 Programs Program management and transfer between machine and ALS 610/09 Programs plus Parameter lists, full text search, program comparison 610/04 Quality Statistical process control (SPC) via actual process values, process sample, interface to quality assurance systems 09/2014 www.arburg.com 5

Powerful information centre Record data everywhere: multi-function terminals also integrate manual workstations. 1 Integrating all machines For ARBURG, all really means all! Regardless of the manufacturer, year of construction and production process, all the injection moulding machines and production systems can be integrated in the highperformance ALS information centre. The following options are available: Multi-function terminals for older machines and manual workstations I/O modules for simple connection of any machines and systems Standardised interfaces for all makes of injection moulding machine Host computer interface for ALLROUNDERs The SELOGICA machine control system interacts optimally with ALS, in particular when functions such as direct access to screen pages, direct recording of fault causes, exchange of setting data or comparison with the order list are involved. Flexible and rapid response to production requirements is the order of the day. The powerful ARBURG host computer system (ALS) provides you with real-time access to your production data, worldwide across all your locations, even enabling remote maintenance. A direct flow of information is ensured through connection to your company-wide production planning system (PPS) or enterprise resource planning system (ERP). You benefit from complete vertical integration from the machine through to material planning, purchasing and sales. Management Production Management ERP/PPS ALS Production Ethernet Ethernet 1 Further information: SELOGICA brochure 6 www.arburg.com 09/2014

2 Central data acquisition ALS enables the central management of part, mould and material master data. This enables you to perform real-time production planning down to the minute through the online recording of order statuses, machine states, process parameters and alarm messages. With this precise information, you are able to quickly and flexibly respond to the constantly changing requirements. Optimum cost-efficiency in production is thus ensured throughout. The combination of machine and production data acquisition (MDA and PDA) allows you make target/actual comparisons, to optimise processes and reduce set-up times. All occurring events are immediately registered via continuous status monitoring. 3 Comprehensive data provision Constantly up-to-date production data benefits your planning system. Order data is adopted by the planning system, feedback on order progress is provided by ALS. You can choose where, when, how and which information is made available to you: from the smartphone to the flatscreen. This results in significantly fewer internal queries regarding the status of production orders. 2 Central data acquisition 1 3 Comprehensive data provision Integrating all machines 09/2014 www.arburg.com 7

Preventive quality assurance 1 Convenient archiving of setting data ALS facilitates the fast retrieval of the relevant data for a certain production combination, such as machine/peripheral/mould/material. As well as the setting data, setting logs and the corresponding screen pages can be archived simply and reliably. Furthermore, the creation of parameter overviews from archived setting data is just as quick and easy as the direct comparison between two data records with detailed indication of potential differences. Documentation of the settings can thus easily be achieved during a batch or a running order. Central access: optimised and approved setting data. Know-how is virtually priceless. Consequently, you should treat your setting data with the greatest of care. The ARBURG host computer system (ALS) provides you with secure collection and archiving of your important data. Only the most recent, optimised and approved change status reaches your machine, the possibility of outdated setting data being used is excluded. Diskettes and memory cards are a thing of the past. You receive fully reproducible product quality and minimise complaints an excellent prerequisite for successful audits and certifications. 1 Convenient archiving of setting data 8 www.arburg.com 09/2014

2 Active improvement of product quality The monitoring and documentation of changes in the production process with the recording of the actual process values makes the quality of your production train particular when functions such asin particular when functions such asceable. The product-specific management of reference values and tolerance bands for the current actual values contributes towards increased production and product quality. Warnings can be output with regard to imminent quality deviations. You can then respond quickly and proactively, without having to interrupt production. 3 Verifiable process quality The order-specific archiving of actual process values provides documented evidence of the quality of your production process. Detailed long-term analyses, statistical evaluations and proof of process capability, for example according to ISO TS 16949, can be implemented. Furthermore, close networking with quality assurance systems is possible. 2 Active improvement of product quality 3 Verifiable process quality 09/2014 www.arburg.com 9

Efficient production and resource management Ideal for unmanned shifts: active, instant feedback via SMS or e-mail. 1 Central order management Your order planning prompts the provision of the necessary setting data, the relevant mould and the required material. The setting data is transmitted directly to the machine when production of the order commences. You ensure a high degree of integration, interaction and automation of your production facility while ensuring intelligent production. 2 Machine capacity planning By planning your machine capacity down to the last minute via ALS, you achieve comprehensive time and cost savings: perfect utilisation of available capacities, precise information on the relevant manpower requirements, minimisation of set-up times and also the co-ordination of necessary interruptions in production all made possible by ALS. The irregular aspects of injection moulding production such as family The clearly structured order planning and monitoring via the ARBURG host computer system (ALS) enables efficient production management. A high degree of planning reliability is ensured by the direct assignment of orders to machines and by the formation of order queues in the plan table. The proactive fine planning and co-ordination of machine allocation, order situation, production deadlines and unit volumes as well as maintenance work lend transparency to even the most complex production requirements. You are able to manage the available production resources reliably and with ease. For ARBURG, smooth, automatic data exchange with planning systems such as SAP is a matter of course. Machine capacity planning Reliable delivery Maximisation of availability Central order management 10 www.arburg.com 09/2014

moulds, defective cavities, mould inserts, master moulds, additional peripherals or machines with different performance can be incorporated into the fine planning. Targeted information exchange also supports departments such as warehousing, mould making or service in organising their operations. 3 Reliable delivery The current scheduling status at a glance: fast and specific order clarification with active display of bottlenecks and potential deadline issues means you can provide information on an ad-hoc basis. Countermeasures can be implemented in good time and production and delivery deadlines can be reliably met. This preventive processing of orders ensures a high degree of customer satisfaction. 4 Maximisation of availability With ALS, you can centrally manage and document your maintenance orders for moulds, machines and peripherals. The continuous monitoring of due dates and automatic reminders for forthcoming work via SMS, e-mail or info screen protect you from unscheduled machine downtimes. In this way, you secure your production quality in the long term through preventive maintenance. 2 3 4 1

Comprehensive documentation and archiving Well-founded information: data evaluation at the press of a button. 1 Continuous recording of data ALS offers you long-term documentation, reliable and with no effort on your part. Of production sequences with recording of all relevant events. Of order progression with documentation of all events during production of the order, including batch monitoring in the form of an order log. Of parameter changes with recording of all trends and developments in comparison with the specified setting data. These measures all render your production operations more transparent. ALS therefore provides you with an ideal basis for comprehensive complaints management and seamless quality documentation with regard to all your customers. You are ideally equipped for certifications according to GMP, FDA, ISO TS 16949 and ISO 9001. Ensure ongoing production optimisation through the continuous identification of potential improvements. Well-founded information forms the basis for professional decisions. This well-founded information is provided by the ARBURG host computer system (ALS) with all the important key data and statistics, you are always right upto-date. The fact that the recorded data is presented in a clearly structured manner at the touch of a button makes ALS all the more attractive. A significant benefit is that the available data can also be used during the decision-making process relating to capital investments. Knowledge has always been preferable to speculation. 2 12 www.arburg.com 09/2014

2 Targeted analysis Targeted analyses become child s play. Whether the productivity of machines and moulds or the cost-effectiveness of orders and articles are under examination, the modular ALS modular production management system helps you complete this with a high degree of clarity. For this purpose, a large selection of predefined reports are available. Moreover, data exchange for the further processing of recorded production data using standard software tools is of course always possible. This allows even highly specific evaluations to be made simply, quickly and reliably. 3 Central document networking ALS provides fast access to productionrelated documents, such as work instructions, test schedules, parts lists and drawings. Through direct linking to master data, setting data and orders, the current availability of documents and the absence of paperwork, you receive an efficient information management system. Comprehensive and always centrally available. 1 Continuous recording of data Targeted analysis 3 Central document networking 09/2014 www.arburg.com 13

Application examples 1 2 Individual info screens: free selection from various widgets provides for on-site transparency. Worldwide networking: ALS is available in numerous languages. ALS offers you a wide variety of functions to enable you to implement your specific requirements for an efficient and economical production organisation. Thanks to the flexible, modular concept, precise adaptation to different applications is comprehensively ensured. This may involve quantity recording, simple connection to I/O modules, detailed fine planning of available capacities or management of the mould store. And you can be sure of one thing: ALS considerably simplifies your data handling and allows you to optimise your production in a targeted manner, including time and cost saving. 1 Creating transparency From smartphone through to large flatscreen in production: with ALS, you can configure customised info screens browser-based and completely platformindependent. Depending on the location and purpose of use, any number of different info screens can be combined, e.g. for alarms as a machine control station, for increased reject rates as a quality chart or for orders as a production overview. In addition, a wide range of graphic design options allows you to present the collated information in your corporate design. 2 Access to all sites ALS is the ideal tool to help you retrieve all important production data for your worldwide locations. A standard network connection is all you need to be able access fault messages, downtime causes, production progress, key figures such as OEE, availability and quality rate at the touch of a button. And not only for ALLROUNDER injection moulding machines, but for all production systems! However, remote access via ALS is also a useful service tool. Quick assistance from ARBURG Customer Service is therefore instantly available to you. ALS modules in use: Web I/O alarms Info Progression ALS modules in use: Mobile Programs Reports 14 www.arburg.com 09/2014

3 4 5 Interactive checklists: a useful aid so that nothing is forgotten. Automatic mould provision list: direct feedback via touch terminal. Validated processes: production release via handheld unit. 3 Coordinating maintenance With ALS, you can document the event history of machines, moulds, peripherals and other equipment in the long term and extremely reliably. Shot counts, operating hours, set-up processes etc. are determined automatically and directly recorded. Due dates for maintenance work are constantly monitored you receive advance warning in good time via SMS or e-mail. In addition, ALS supports you in the performance and documentation of maintenance work, e.g. instructions, checklists, reports or electronic signatures can be stored. 4 Optimise set-up processes Even at the order planning stage, ALS takes account of the storage location and availability, including master mould, inserts and accessories. Current provision lists are automatically generated. Mould management, a touch terminal for stock movements and scanner support are also provided. Moulds can therefore be provided particularly quickly and efficiently. ALS transfers the data record of the next order online to the SELOGICA machine control. Set-up personnel are therefore provided with the mould and data record in good time on the machine and can start the set-up immediately. 5 GMP-compliant documentation On the basis of a central machine control, you can use ALS to define production combinations (e.g. machinery-peripheral-mouldmaterial) for order planning. This means that there is only one validated data record for each production combination. You can control production release via user identification with an RFID card and an ACTUAL- TARGET comparison via a scan. ALS then offers you GMP-compliant process documentation at virtually no extra cost: from the continuous logging of process parameters and seamless batch tracking through to long-term archiving of set-up logs and recalibrations. ALS modules in use: Maintenance Groupware Documents ALS modules in use: Terminal Programs Orders Reports ALS modules in use: Mobile Programs Orders Quality Set-up log Batch 09/2014 www.arburg.com 15

ARBURG GmbH + Co KG Postfach 11 09 72286 Lossburg Tel.: +49(0)7446 33-0 Fax: +49(0)7446 33-3365 www.arburg.com e-mail: contact@arburg.com With locations in Europe: Germany, Belgium, Denmark, France, United Kingdom, Italy, Netherlands, Austria, Poland, Switzerland, Slovakia, Spain, Czech Republic, Turkey, Hungary Asia: People s Republic of China, Indonesia, Malaysia, Singapore, Thailand, United Arab Emirates America: Brazil, Mexico, USA For more information, please go to www.arburg.com. 2014 ARBURG GmbH + Co KG The brochure is protected by copyright. Any utilisation, which is not expressly permitted under copyright legislation, requires the previous approval of ARBURG. All data and technical information have been compiled with great care. However, we are unable to guarantee its correctness. Individual illustrations and information may deviate from the actual delivery condition of the machine. The relevant valid operating instructions are applicable for the installation and operation of the machine. ARBURG GmbH + Co KG DIN EN ISO 9001 + 14001 + 50001 certified 523904_EN_GB_092014 Subject to alterations Printed in Germany