1 Fis Users Guide v2.3

FIS USERS GUIDE Factory Information System

Release 2.3 October 30, 2007

00 FIS USERS GUIDE.doc i 10/30/2007

Table of Contents Table of Contents ................................................................................................................................ i 1 - Introduction to the FIS.................................................................................................................. 1

Functional Overview...................................................................................................................... 1 FIS Applications ............................................................................................................................ 2 Who Benefits from FIS? ................................................................................................................ 4 Quick Start Table ........................................................................................................................... 5

2 - FIS System Architecture............................................................................................................... 7 Network Operation......................................................................................................................... 7 FIS Network Devices ..................................................................................................................... 8 Remote Operation .......................................................................................................................... 9

3 - Process Equipment ..................................................................................................................... 11 Plant ............................................................................................................................................. 12 Area.............................................................................................................................................. 12 System.......................................................................................................................................... 12 Machine........................................................................................................................................ 13 Station .......................................................................................................................................... 14 Element ........................................................................................................................................ 14 Message (PLC I/O) ...................................................................................................................... 14

4 Equipment Diagnostics .............................................................................................................. 16 Machine States ............................................................................................................................. 16 Machine Conditions ..................................................................................................................... 17 Logged Events and Active Events ............................................................................................... 18 Cycle Times ................................................................................................................................. 18 Part Counters................................................................................................................................ 18 Accumulator Counters ................................................................................................................. 19 Process Variables ......................................................................................................................... 19

5 Application Navigation.............................................................................................................. 20 Running an Application ............................................................................................................... 20 FIS Analysis Tools....................................................................................................................... 21 FIS Real Time Applications......................................................................................................... 21 FIS Tools...................................................................................................................................... 21 FIS Application Window ............................................................................................................. 22 Title Bar ....................................................................................................................................... 22 Menu Bar ..................................................................................................................................... 23 Tool Bar ....................................................................................................................................... 23 Status Bar ..................................................................................................................................... 23 FIS Application Configuration Files............................................................................................ 24 Saving a File ................................................................................................................................ 25 Loading a File .............................................................................................................................. 25 Closing a File ............................................................................................................................... 25 File Naming Conventions ............................................................................................................ 25

6 FIS Real Time ............................................................................................................................ 26 What Is FIS Real Time?............................................................................................................... 26 User Responsibilities ................................................................................................................... 26 Accessing Machine Status ........................................................................................................... 26

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Selecting a Display List ............................................................................................................... 27 6a Accumulator Monitor............................................................................................................... 31

Accumulator List.......................................................................................................................... 31 6b FIS Cycle Time Monitor.......................................................................................................... 33

Cycle Time List............................................................................................................................ 33 6c FIS Fault Alarm Monitor ......................................................................................................... 35

Fault Alarm List........................................................................................................................... 35 6d FIS Graphics ............................................................................................................................ 37

Graphics ....................................................................................................................................... 37 Accessing FIS Graphics ............................................................................................................... 37 Plant Overview Screen................................................................................................................. 37 Zoom Files................................................................................................................................... 38 Legend Display............................................................................................................................ 38 Zoom to an Area .......................................................................................................................... 38 Graphical Zoom Detail Breakdown ............................................................................................. 38 First Level (Area)......................................................................................................................... 39 Second Level (Zoom to Faults).................................................................................................... 40 Single Machine (Zoom to Machine Status) ................................................................................. 41 Element List ................................................................................................................................. 42

6e Process Variables Monitor ....................................................................................................... 44 Process Variable List ................................................................................................................... 44

6f FIS Status and Production Monitor .......................................................................................... 45 Part Counter List .......................................................................................................................... 47

7 FIS Analysis Tools..................................................................................................................... 48 7a FIS Charting ............................................................................................................................. 49

Process Variable Chart................................................................................................................ 49 View / Print Process Variable Chart Data.................................................................................... 52 Process Variable Statistics ........................................................................................................... 52 Accumulators Chart ..................................................................................................................... 52 View / Print Accumulator Chart Data.......................................................................................... 54 Accumulator Statistics ................................................................................................................. 54 Charting from within FIS Graphics ............................................................................................. 55 Auto Update ................................................................................................................................. 55

7b FISMPI..................................................................................................................................... 56 Functional Overview.................................................................................................................... 56 Industry-Standard Performance Indicators .................................................................................. 56 Quality Data ................................................................................................................................. 57 Adjustable Scheduling ................................................................................................................. 57 Production Targets ....................................................................................................................... 57 Aggregate Indicators .................................................................................................................... 57 Machine State Consolidation ....................................................................................................... 58 Machine State Profiles ................................................................................................................. 59 Indicators...................................................................................................................................... 60 Profile-Based Indicator Components........................................................................................... 60 Machine Breakdown Time........................................................................................................... 60 Documented Stoppage Time........................................................................................................ 60 Non-Productive Time................................................................................................................... 60 Setup and Adjustment Time......................................................................................................... 60 Tooling Loss Time ....................................................................................................................... 61 Blocked Time............................................................................................................................... 61

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Cycling Time ............................................................................................................................... 61 Other Indicator Components........................................................................................................ 61 Unplanned Downtime .................................................................................................................. 61 Net Available Time...................................................................................................................... 61 Machine Performance Indicators ................................................................................................. 61 AVAILABILITY ......................................................................................................................... 62 QUALITY.................................................................................................................................... 62 PE................................................................................................................................................. 62 MTTR .......................................................................................................................................... 62 MTBF........................................................................................................................................... 62 OA................................................................................................................................................ 63 PA ................................................................................................................................................ 63 Actual JPH ................................................................................................................................... 63 SAJPH.......................................................................................................................................... 63 SAA.............................................................................................................................................. 63 ISA ............................................................................................................................................... 64 OSA.............................................................................................................................................. 64 DIA .............................................................................................................................................. 64 MPI User Interface....................................................................................................................... 64 Launching the MPI Application................................................................................................... 64 The MPI Analysis Workspace ..................................................................................................... 67 Active Machines List ................................................................................................................... 67 Summary Options ........................................................................................................................ 68 Export to Excel ............................................................................................................................ 68 Sorting Indicators......................................................................................................................... 68 Select / De-Select rows for charting ............................................................................................ 68 Chart Selection List...................................................................................................................... 68 Display Preferences ..................................................................................................................... 69 MPI Trend Chart Features ........................................................................................................... 69 MPI Stacked States Chart ............................................................................................................ 73 Other Charting Features ............................................................................................................... 74 Bad Part Data Entry ..................................................................................................................... 75 Aggregate Indicators .................................................................................................................... 77

7c - Reports ...................................................................................................................................... 78 Report Types ................................................................................................................................ 78 Starting Reports ........................................................................................................................... 78 Standard Report Option Controls................................................................................................. 80 Machine Selection........................................................................................................................ 81 Viewing Format ........................................................................................................................... 81 Report Type ................................................................................................................................. 81 Production Times ......................................................................................................................... 81 Date Control................................................................................................................................. 82 By Time Interval .......................................................................................................................... 82 Alarms Report .............................................................................................................................. 83 AVI Read Performance Report .................................................................................................... 84 Cycle Time Report ....................................................................................................................... 85 Cycle Time Report Examples ...................................................................................................... 87 Cycle Time Report Definitions.................................................................................................... 88 Lost Production Report ................................................................................................................ 89 Machine Status............................................................................................................................. 89

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Machine Status Report Definitions.............................................................................................. 94 Machine Performance Report ...................................................................................................... 95 Process Variables Report ............................................................................................................. 96 Production Counts........................................................................................................................ 97 Status and Production Report..................................................................................................... 101 Status and Production Report Definitions.................................................................................. 101 Data Integrity Report ................................................................................................................. 102 Data Integrity Report Definitions .............................................................................................. 103 Saving Machine Lists................................................................................................................. 106 Opening A Saved File ................................................................................................................ 107

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1 - Introduction to the FIS Functional Overview

The Factory Information System (FIS) is a plant monitoring system that provides for the automatic collection and display of current and historical process data. FIS collects information from Programmable Logic Controllers (PLCs), archives this

information in a database, and then displays the data on demand from desktop PCs, Programmable Workstations (PWS), scrolling marquees, Andon boards, and Pagers. The primary focus of the FIS system is on the performance of process machinery and not on the characteristics or quality of the actual product being manufactured. Another important aspect of FIS is that is serves strictly as a monitoring tool and does not control process machinery. Performance data for process machinery is rendered through the use of real-time displays and analysis tools. The real-time displays permit plant floor personnel to quickly respond to critical process problems as they occur in order to maximize process uptime. The analysis tools allow plant and corporate personnel to analyze long-term performance measures through the generation of detailed and summarized reports, trend charts and graphs.

The purpose of the FIS system is to assist plant and corporate personnel in the continuous improvement of the performance of manufacturing processes through the following:

Real-time visualization of the operation of plant floor machinery which enables the rapid identification and resolution of process problems and bottlenecks.

Trending of shift and daily production data to assist in day-to-day production scheduling decisions.

Reporting of long-term machine efficiency indicators to measure the effectiveness of continuous improvement initiatives and to eliminate process bottlenecks.

The following outlines the primary features of the FIS system:

Machine States - FIS reports on the state of each piece of plant floor machinery that is controlled from a PLC. The following are examples of commonly used machine states:

MACHINE STATE TYPE

IN CYCLE Normal Operation FAULT Machine Breakdown OUT OF AUTO Machine Breakdown POWER OFF Machine Breakdown STARVED Machine Stoppage BLOCKED Machine Stoppage PROD STOP Machine Stoppage COMM FAULT Data Collection Problem

Machine states are prioritized when presented in FIS displays. The displays show the current state and state history of monitored equipment including:


- Elapsed time of the current machine state - Total time duration for a given state for the current shift - Number of occurrences for a given state for the current shift

Machine Breakdowns A basic feature of FIS is the immediate identification of machine breakdowns. A breakdown is a condition that prevents the machine from running normally and will usually require intervention by maintenance personnel in order to fix the problem. In FIS, each prohibitive I/O is identified and organized in a prioritized display. With the aid of this display, maintenance personnel can "clear" all prohibitive conditions and sequence the machine in order to return it the IN CYCLE state. The original cause of the fault condition is archived in a database so that it is included in all FIS analysis functions.

Alarms FIS has the ability to warn plant personnel of impending problems through the

alarm feature. Alarms are essentially warnings that may occur while the machine is cycling normally. While they may not require immediate attention, Alarms identify conditions that may eventually result in a machine failure or stoppage. MATERIAL CALL, LOW LUBE LEVEL, and TOOL WARNING are examples of alarm conditions.

Cycle Times - FIS keeps a detailed record of machine cycle times, allowing plant

personnel to evaluate if the machinery is performing to design specifications. FIS records invalid cycle times (a cycle time that exceeds established high or low limits) based upon a previously determined standard. FIS also displays the number of times an invalid cycle time was detected, making it simpler to establish the probable impact on production.

Production Counts - FIS displays a running total of the number of parts produced for the

current hour and shift for any machine that has part counters associated with it. The system can show the variance between actual and target production counts.

Accumulator Counts - Accumulator counts are displayed in real-time as parts pass in

and out of equipment zones. High and low accumulator thresholds can be set in order to signal conditions that may cause process blockages.

Process Variables Although the FIS system is primarily concerned with discrete

processes, continuous process conditions such as temperatures, pressures, humidity, and volume can be monitored and recorded through the use of Process Variables. Users can display the current readings for any process variable in real time, or launch a historical chart that shows long-term trends associated with such process points.

FIS Applications The Graphical User Interface (GUI) for FIS runs under Microsoft Windows 2000 or Windows XP, and conforms to Windows-standard design practices. All real-time and historical information can be accessed through the use of five basic FIS applications. Each application is launched from an IWS via the "Start", "Programs", "Factory Information System" menu sequence by Windows. Later in this manual, a detailed explanation of each application is presented. Figures 1.1 1.5 show a typical view of each application with a brief description of the application:


Machine Status - A tabular list of a group of machines with real-time display

of machine states, current machine events, production counts, machine cycle times, accumulator counts, and process variable readings. Users can select any machine from the list and drill down to obtain detailed statistics for the selected machine. Historical logs can be launched that show machine states, counts and cycles in a chronological list or chart format.

Figure 1.1 Machine Status Application

Graphics Real-time animation of CAD-like graphical views of plant

areas, departments, lines, and machines. Graphic displays show plant process topology with animation of process machines, interconnecting conveyors, and part accumulation lanes. Users can zoom to detailed graphic displays that show sections of the plant that cannot be fully rendered on a higher level display. All graphics use a standard color coding convention to easily identify process problems.

Figure 1.2 Graphics Application

Charting Generates charts from the reading of accumulators and process

variables over any selected date/time range. An option to display high/low fault/alarm limits is also included. The application also includes a feature for overlaying trends from various sources for easy comparison. Although charts can be launched by other FIS applications, the Charting Application is offered as a convenient and quick way to launch a chart for a specific type and range of data.

Figure 1.3 Charting Application


Reports - Provides the capability for a user to generate, save, and print

reports related to machine performance and production statistics. Detailed or summary reports can be selected for any date range up to one year. Results can be exported to any one of a number of popular formats like CSV, XLS, and HTML. All reports are ad hoc in nature, i.e. they are not pre-generated and stored for later retrieval. Reports are generated on demand based on any selection criteria specified.

Figure 1.4 Reports Application

Machine Performance Indicators (MPI) Used for long-term

analysis of machine performance and identification of process bottlenecks to improve plant efficiency. This tool supports trending of many industry-standard indicators such as Overall Equipment Effectiveness (OEE), Mean Time To Repair (MTTR), Mean Time Between Failure (MTBF), and Stand-Alone Jobs Per Hour (SAJPH). Alternate schedules can be applied for short-shift and tag relief events.

Figure 1.5 MPI Application Who Benefits from FIS? FIS addresses monitoring requirements common to discrete and continuous manufacturing processes such as stamping, machining, welding, paint and assembly. No restrictions are imposed with respect to "who" can view "what" from "where". All information processed by FIS is available to all plant and corporate personnel from any IWS (desktop or laptop personal computer) that is connected to a plant or corporate network. Skilled Trades, Line Supervisors, Process Engineers, Center Managers and Plant Managers, can all utilize the FIS system. The following outlines just a few of the benefits that can be derived by the various disciplines: Skilled Trades use the Graphics and Machine Status applications for notification of

conditions that cause machine downtime. Notification can also be obtained through the observation of marquee displays installed throughout the plant or with personal paging devices. Detailed (or drill-down) screens aid in troubleshooting the exact cause of a problem and steps required for repairing and sequencing the machine. The performance history of the


equipment can also be used to develop Preventive Maintenance (PM) schedules as well as provide data for failure analysis.

Line Supervisors can use the part count, trending and production targeting features to

determine if there is a need to move an operator up the line or down the line to enhance overall throughput. Predictive part count analysis can aid in making short-term scheduling decisions. Production reports can be used to evaluate long-term production performance.

Engineers can fine tune a process based on the analysis of cycle performance. Reports on

overall machine performance aid in providing feedback to original equipment manufacturers. Process equipment suppliers can be evaluated on their ability to meet the original performance specifications. The data gathered from cycle time reports can also be used to adjust downstream line speeds and manpower distribution, identify production bottlenecks, and establish optimum equipment cycle time.

Plant Managers and Center Managers can use the MPI and Reports applications to

evaluate overall system efficiency and throughput. Long-term trend charts can pinpoint performance issues with respect to production or maintenance.

In summary, FIS is a tool designed to assist plant and corporate personnel in daily troubleshooting and long-term decision-making processes. Improving uptime and productivity is the ultimate goal, and FIS is one part of the strategy to achieve this goal. Like any other tool, however, FIS must be maintained in order for it to convey accurate data. Therefore, keeping the FIS configuration up to date is essential in insuring that the tool is properly used. It is extremely important that parameters such as machine design times, part counts, machine state diagnostic PLC logic, and area production schedules are as accurate as possible. While the purpose of this manual is not to cover the configuration of FIS, it is important that the user understand that only through the proper configuration of FIS will it provide the promised benefits. See the FIS Configuration Manual on the FIS Web site for more information. Quick Start Table The following table serves as a quick reference to each of the chapters included in this manual:

If you want to Then

Gain a general understanding of the purpose of the FIS System

See Chapter 1, Functional Overview. This chapter serves as an introduction to FIS for new users.

Learn more about the infrastructure of the FIS System and the devices that the system supports

See Chapter 2, FIS System Architecture. This cha pter gives the user a high-level description of how FIS collects data from various plant floor devices and explains how FIS information is disseminated to the end-user via the plant and corporate networks.

Understand how FIS organizes plant process machinery

See Chapter 3, Process Equipment. In this chapte r, a detailed explanation of the layout of equipment from the highest (plant) level down to lowest (message) level is presented. Sample graphic displays are used to visualize each plant component.


Become familiar with the basic diagnostic and monitoring functions offered by the FIS system

See Chapter 4, FIS Diagnostics. This chapter exp ands on the concepts presented in Chapter 1 with regard to the various monitoring functions supported by the FIS System. It will familiarize the user with terms that are common to FIS such as Active Event, and Logged Event. It will also e nable the user to interpret the various displays and reports in FIS.

Learn how to navigate through FIS applications

See Chapter 5, Application Navigation. This chap ter describes the drill down technique, which is common to most FIS applications. It also illustrates how FIS uses pull down lists, menus, pop-ups and other functions common to Windows compliant applications.

Use FIS to monitor the day-to-day performance of the manufacturing process

See Chapter 6 FIS Real Time. This chapter explai ns how to launch and interpret the information presented on graphical and tabular real-time displays. Also included are instructions to create user-defined displays and shortcuts to frequently used displays.

Use FIS to analyze the performance of the manufacturing process

See Chapter 7, FIS Analysis Tools. This chapter explains the three basic analytical tools supported by FIS: Reports, Charting, and MPI.


2 - FIS System Architecture The purpose of this section is to convey an understanding of the FIS System Architecture. Although the average user is generally not concerned with "how it works", a basic knowledge of the underlying data collection process is beneficial. Figure 2-1 shows a typical configuration of the principal hardware components that support the FIS system. The reader should refer to this figure in the following discussion.

Network Operation All communications between devices within the plant is achieved via a Local Area Network (LAN). A LAN is a high-speed network that services various computers, printers, and other intelligent devices within a relatively small area such as a plant or segment of a plant. The jurisdiction of a typical LAN is normally restricted to one building, or between buildings with a radius of no more than a mile. Two Local Area Networks, the Plant Automation Network (PA) and the Office Automation Network (OA), interconnect the plant floor devices and display terminals that service FIS. FIS shares these networks with other standard DaimlerChrysler plant systems such as PFS, PFCS, AVI, SPC, and QAS. The PA network is primarily responsible for communications among plant floor devices that control machinery. The OA network services all office devices such as Application File Servers, Database File Servers and Desktop computers. The OA and PA Networks are interconnected with a Firewall , which serves to prevent unauthorized entry into the PA network from the OA network.

WCC #3 AIX 5.3

IBM p520

to: Plant Pagers

First PAGE Server

Windows 2000

CAS

IWS Windows 2000/XP

WCC #2 AIX 5.3

IBM p520

Marquee Mgr. Server

Windows 2000

Router

Scrolling Marquee Andon Board (Line or Full Matrix)

PA

Terminal Server

Networked PLCs

WCC #0 AIX 5.3

IBM p520

WCC #1 AIX 5.3

IBM p520

FIS Database

Server AIX 5.3

IBM p520

Figure 2.1 FIS System Architecture

OA

PA

OA


The Wide Area Network (WAN) connects the components of a multiple station computer system on a larger scale. The DaimlerChrysler WAN interconnects all LANs within the corporation. Response time for communications across the WAN is slower than that achieved via the LAN. This is due to the fact that communications packets must traverse through a series of network Routers that are responsible for interconnecting seperate LANs within the WAN. FIS Network Devices FIS makes extensive use of the plant LANs and the corporate WAN in order to service a vast user base. All devices that communicate across plant and corporate networks are described here, starting with the plant floor machinery up through to the desktop computer. Plant automation machinery is controlled by Programmable Logic Controllers (PLCs). Each PLC on the plant floor contains special diagnostic logic that is responsible for sending machine-related data to a Work Cell Controller (WCC). Data packets called "Data Blocks" are sent to the WCC via the Plant Automation (PA) Network. This data is sent any time there is a change in machine status that needs to be annunciated on a display device such as an Intelligent Work Station (IWS), Pager, Marquee Display, or stored in a Historical Database for later retrieval. A typical plant will have hundreds of PLCs and anywhere from 3 to 5 WCCs. The WCC can be thought of as a data concentrator. It stores information provided by the PLCs in a real-time database. The real-time database was specially designed to store and forward real-time data in an extremely efficient manner. The WCC will deliver changes in plant conditions to any display device on the Local Area Network within 2 seconds of the original transition. Naturally, changes delivered to display devices across the corporate WAN will take longer. As data on the WCC ages, it is periodically written to the Historical Database, which currently resides on a Sybase File Server. The frequency at which the Historical Database is updated varies based on the type of data being collected, but generally WCC data is archived within minutes after its initial creation. The Historical File Server has the capacity to store one years worth of process data. This includes all machine state changes, hour and shift counts, cycle times etc. that occurred during a running year. Access to real-time and historical data is achieved through the use of an IWS, which is simply a desktop computer running Windows 95 or Windows 2000 and connected to the OA Network. When a real-time display is launched by the user, a request for notification is sent to the WCC from the IWS. This request informs the WCC that the IWS should be notified whenever process data on the display changes. Windows software that resides on the IWS is responsible for interpreting all incoming data and updating the appropriate graphic or text objects on the display. When the graphic window is closed, the IWS sends the WCC a request to terminate notifications from the IWS. Although the IWS usually refers to a desktop computer, it can also be a laptop computer. The following chart summarizes the major network devices that contribute to the operation of FIS.


Device Function Programmable Logic Controller (PLC)

The device that controls plant machinery. Both the control logic and FIS diagnostic logic reside on the PLC. The FIS diagnostic logic sends event data blocks to the WCC when a change in machine status (i.e. part counters or machine states) occurs.

Workcell Controller (WCC)

A data concentrator that interprets the data blocks sent by the PLC and converts them to a format usable by the Historical Database and Intelligent Work Stations.

Historical File Server

Acts as a storage and distribution center for all historical data available to FIS.

Intelligent Work Station (IWS)

Provides the user access to the data and displays the data as text and graphics

Remote Operation Typically, a plant IWS will make a default connection to WCCs and File Servers that reside on the plant network in order to launch displays pertinent to that plant. However, the occasion may arise when the user needs to access data from another plant. In fact, this is the typical mode of operation for the mobile user. FIS provides the ability for the user to change the default plant, or make a remote connection to devices outside of the local network.

The Change Default Plant Application allows you to change the Plant that is accessed each time any FIS32 Application is started. This may be used by anyone to access and

view another plants FIS system. However, the number of remote connections is limited to 32 per WCC. An FIS32 connection is considered remote if you are at one Plant and change the default to another Plant or if you are connecting from your home or a remote site. FIS Change Default Plant can be started using the following method. From Windows taskbar, click Start > Programs > Factory Information System > FIS Tools > FIS Change Default Plant. The following window will open displaying the current default plant at the top of the application window.

Follow these steps to change the default Plant: 1) Close all FIS Applications 2) Click the button Click to Change Default Plant. 3) The following list will appear.


4) Click on the desired plant to select and click OK to change or dbl-click the Plant to change. After you have made a change the window will collapse to save space.

5) You may click Cancel if you do not wish to change the plant. This will cause the window to collapse to save space.

6) Click the X on the upper right hand corner of the window to close the application.

Tip You may leave the Change Default Plant Application open if you are switching between multiple plants.


3 - Process Equipment This section describes the organization of process equipment and defines commonly used terms with regard to FIS. Figure 3-1 shows an example equipment layout of an assembly plant. Notice that the layout follows a natural hierarchy, starting with the Plant at the highest level to Messages (input / output or control point) at the lowest level.

Figure 3-1 Equipment Layout Each level in the hierarchy is described in detail as follows:


Plant Assembly, Component, Power Train, and Stamping plants are some of the obvious examples here. The plant can be selected using the "Change Default Plant" application as was discussed in Section #2 - Remote Operation. Area An area of the plant. Examples of areas found in DaimlerChrysler plants are shown in the table below. Usually, areas are assigned by major process or by product line. The most significant aspect of them is that production schedules are configured by area. For example, in an assembly plant, it may be necessary to stagger shift start and end times across the major process areas. The FIS system accommodates this through the use of the FIS Scheduler which is explained in more detail later on in this manual.

Powertrain Areas are assigned by major machining or assembly area: Engine Assembly, Piston Assembly, Bedplate Machining, Finish, Filters

Assembly Areas are assigned by major process area: Body in White, Paint Shop, Trim Chassis Final

Stamping Areas are assigned by product line: JA Hood, JA Left Rear Door, WJ Left Body Side

System A System is a logical grouping of machines. The System is used primarily as a criteria for machine selection in FIS, and actually has little significance from a diagnostic standpoint. Figure 3-2 shows an example of a machine selection dialog box that includes a description of each system and their associated machines in tree view form.

Figure 3-2 Machine Selection Dialog using Systems Here, the Glass System in the Assembly Area (ASM) has been expanded so that all of the individual machines under that system are shown. FIS is configured such that machines are


grouped according to logical process, line or operation. The generic terminology that FIS uses for these groupings is System. Some examples of Systems are the following: Underbody System, Door System, Head Line Operation #3, Engine Assembly Zone C, Brake System, Paint Oven System, etc. Machine A Machine is best described as a section of process machinery that runs as a synchronous unit. While a machine may have adjacent upstream or downstream conveyors, it is always identified by the fact that all of its components (transfers, stations etc.) run in synchronism. Conveyors are treated as a separate machine from a process machine because they run independently of the process machine. An example is given in the graphical view of an Aperture Respot Machine shown in Figure 3-3.

Figure 3-3 Aperture Respot Machine

The Aperture Respot Machine contains seven individual stations, shown in the figure as S01 - S07, interconnected with a shuttle bar or ARS XFER station. S01 and S07 are carrier pushers, which serve to load (S01) and unload (S07) parts from the adjacent conveyors. S02, S03, S05, and S06 are stations where various welding operations take place, while S04 serves as a part positioner. When all stations have completed their work, the shuttle bar transfers each part to the next station where it is clamped after coming to rest. Once clamped, weld robots at each station are permitted to advance, perform the weld sequence, and return. At this point, the cycle starts all over again. The important concept here is that all stations, including the shuttle, run in synchronism with one another, and therefore, the entire operation is treated as a machine. The Aperture Respot

Elements

Stations


machine is cyclical in nature because it runs in discrete cycles. Other machines, such as conveyors, are non-cyclical because they have no discrete machine cycle and are running continuously. Station For a cyclical machine, a station is a transfer, center-base, or location where the part comes to rest in order for work to be performed. FIS considers S01 - S07 and the ARS XFER each to be individual stations of the Aperture Respot machine. For a non-cyclical machine such as a conveyor, the station refers to a conveyor section that is controlled by an individual drive motor. FIS performs diagnostics at the station level. States, cycle times, part counters, and accumulator counts are all associated with a station and can be accessed via FIS real-time displays using machine/station selection options. Another important concept is that of a Composite Station. A composite station is an abstract station that is always configured for machines with multiple stations. For example, the Aperture Machine has a composite station in addition to the eight functional stations previously described. The purpose of the composite station is to maintain the state of the station that currently has highest priority. Figure 3-3 is the composite state of the Aperture Respot. For example, the Aperture Respot Machine shows S01 - S07 in WHITE, which indicates that these stations are CYCLING normally. The ARS XFER is shown in RED, which indicates that this station has a FAULT condition that prevents the shuttle bar from moving. The composite station would therefore show RED, since FAULT is the highest priority state present among all stations of the machine. FAULT is also considered to be the state of the Aperture Respot machine. Therefore, the state of the composite station always reflects the state of the entire machine. Element An Element is an actual working unit or logical unit of a station. The Aperture Respot machine has 4 working units, or elements, at station S02. They are robots R01, R02, R05, and R06. Other examples of Elements are: panel views, drive units, fixtures, process controllers, etc. Graphical displays can be configured at the element to provide element level diagnostics. In other words, a graphic object may be configured to represent an individual element or composite of several elements. Message (PLC I/O) A Message is a detailed textual representation of a machine state or machine event condition. Messages frequently refer to actual I/O points in the PLC. The following table shows the interpretation of the messages and associated machine status given in Figure 3-1. The reader will gain a more thorough understanding of the messages in Section #4, Equipment Diagnostics.

MESSAGE MACHINE STATUS

INTERPRETATION

S01 R02 Tip Dress Disconnected

FAULT Critical process problem causing machine to stop running. Requires intervention by maintenance personnel to correct.

Blocked Downstream

BLOCKED DOWN

Downstream process machinery not running, causing back up of parts. Machine will automatically resume cycling once the unload station is emptied.


S01 Operation Material Shortage

ALARM

Parts that feed this machine are loaded manually from a magazine. Alarm condition is triggered when magazine is low of parts. Machine is still running but this condition signals that a critical problem is pending.

S01 Operator Over Cycle Load

PRODUCTION STOP

Machine is waiting for manual load of the next part. Machine will run when part present on fixture.


4 Equipment Diagnostics

FIS reports the current status of every piece of automation equipment. The term "status" means any condition of the machine that is relevant to the diagnoses of equipment performance such as: current and past machine states, machine conditions such as alarms, cycle times, hour and shift production counts, parts in accumulation, process variable readings and set points etc.

Machine States The Machine State identifies the current state of the machine. Table 4-1 lists the most common states found in DaimlerChrysler production facilities. In order to facilitate the

visual interpretation of graphical displays, a common color coding convention is used for each machine state throughout FIS. Shown at the top of the list is the IN CYCLE state. When a machine is in motion it is referred to as being IN CYCLE. All other machine states refer to a condition where the machine is at rest. These inanimate states have various causes such as: operator intervention (PROD STOP), machine problems (FAULT), problems with adjacent machinery (BLOCK UP / DOWN) etc. State Color Code Description IN CYCLE WHITE Machine is running normally. POWER OFF RED No power to plant floor equipment. FAULT RED Any event that causes a machine failure. For example, a transfer advanced limit

switch failure would stop all stations on the machine from cycling until the fault is corrected.

OUT OF AUTO RED Equipment is in manual mode. Any event that drops the machine out of automatic mode is classified with this state.

QUALITY ALERT YELLOW An event that could cause a line stop because of a possible product defect detected from the Quality Alert sub-system. An example of an event that could cause a QUALITY ALERT is a torque tool failure. QUALITY ALERT warnings, or pulls, are reported in the form of ALARMS while QUALITY ALERT failures, or stops, are reported in the form of the QUALITY ALERT state.

END OF TRAVEL YELLOW This state usually occurs on a conveyor system with a sub-system such as a manual-assist hoist that follows a part on the conveyor. An END OF TRAVEL indicates that the operator of the hoist has fallen behind the planned work sequence. Such an event may require a modification to the work routine or it may require an adjustment of the END OF TRAVEL switch location.

PROD STOP YELLOW The machine has been stopped by operator due to a break, lunch, or other condition that requires operator intervention.

BLOCKED UP or STARVED

BLUE Waiting the immediate upstream process or conveyor to load a part into the given process machine. The BLOCKED UP state could be caused by a failure or slow condition on an upstream process machine.

BLOCKED DOWN BLUE Waiting for a part on the immediate downstream process machine to advance. The BLOCKED DOWN state could be caused by a failure or slow condition on a downstream process machine.

MAINT ASSIST RED Usually used for production conveyors to flag a condition where a problem could eventually result downstream if the condition is not serviced immediately. Although the conveyor chain is still running, it may stop unless the problem is corrected. An example of a MAINT ASSIST event might be "DRIVERS DOOR OPEN ON CONV. U1" This event warns maintenance that the door must be closed in order for the part to advance through to the next downstream process.

PM EVENT RED The machine was stopped in order to perform preventative maintenance.

Table 4-1 Machine States


State Color Code Description SAFETY NET RED This state usually applies to conveyor systems and is used as a way to

catch any state of the machine that was not trapped by the diagnostic logic in the PLC. This state has an associated event that is set by the motor starter contact. It is triggered if no other states are present and the conveyor drive is not running. In other words, the SAFETY NET state would occur in the event that the diagnostics were unable to detect the fault condition

SYSTEMS FAULT RED Flags a problem that occurred with control hardware such as an AVI Reader, I/O Control Racks, or other PLC related hardware.

IDLE BYPASS Occasionally, a station with multiple robots might have one of the

robots disabled, or in BYPASS, while one of the other adjacent robots is programmed to perform the work of the disabled rob

UNDEFINED CYAN () THIS STATE OCCURS WHEN NO EVENT MESSAGE HAS BEEN CONFIGURED FOR THE ASSOCIATED EVENT BIT. THE PLANT FIS STAFF SHOULD BE NOTIFIED WHEN THIS EVENT IS ACTIVATION IN ORDER THAT THE EVENT MESSAGE CAN BE

PROPERLY CONFIGURED. Table 4-1 Machine States (Continued)

Machine states are always accompanied by a state message, which is a detailed description of the state condition. For example, PROD STOP might be accompanied with the message, "CAR PRESENT - WAITING FOR CYCLE START". The message description serves to alert maintenance or production personnel as to the actions required resume the cycle. In most cases, the state message corresponds to an I/O point in the PLC or an error code from an intelligent control device such as a robot. Also, a numeric code associated with each state message is given which serves as a convenient reference for FIS configuration personnel.

Machine Conditions Machine conditions are used to alert plant personnel of non-critical process problems. Table 4-2 highlights the various machine conditions. For example, a machine condition such as an ALARM serves as a warning that a more critical problem could eventually result if the condition is not corrected in a timely manner. State Color Code Description ALARM MAGENTA A condition that requires attention but is not critical enough to actually

stop the machine or cause an immediate problem. Alarms are not machine states, therefore, they are never treated as logged events. Alarms actually accompany machine states. However, alarms are archived in a special alarm log, which can be examined via the Alarm Report covered in Section 7c.

SLOW CYCLE CYAN The machine cycle has exceeded the design time specification for the machine. The logged event for the machine in this state is IN CYCLE.

COMM FAULT BROWN Always reported on a machine for the controlling PLC. This condition means that communication was lost between the WCC and the PLC. Although this condition does not represent an actual machine state, it is treated as the logged event for the simple reason that no other state can possibly be reported when communication is lost between the WCC and the PLC. This event could be caused by a failure in the PLC driver, PLC hardware, terminal server hardware, WCC hardware, or WCC driver.

COMM LOST BROWN Communication lost between the IWS and WCC

Table 4-2 Machine Conditions


Logged Events and Active Events Every time a machine enters a new state, the state and the associated message, or "logged event", is archived to a historical log used for reporting purposes. The logged event is defined as that event which originally caused the machine to enter the new state. There may be other residual events that occur as a result of the original event, however, these events are not logged. These residual events are called "active events" because they can remain active during and as a result of the logged event. The active events must be "cleared" before the machine reaches a state where it can cycle again. It is important that the logged event be archived so that reporting functions accurately portray the original cause of the new state condition. On the other hand, active events, with the exception of the logged event if it happens to also be active, are not archived because they are usually irrelevant to the cause of the machine originally entering the inanimate state. The active events are important to maintenance personnel as they can aid in the process of returning the machine to a cycling state. Although, active events are not logged, they are shown on the Current Events display that is covered in Section #5 on Components. Cycle Times An important feature of FIS is the ability to display and record cycle times of the machine. Generally, FIS measures a machine cycle from the occurrence of a "start event" to the time that this same event occurs again. In other words, machine cycle times are measured from start to start. If at any point in the cycle the machine enters an inanimate state, timing of the cycle is stopped and will not restart until the machine resumes in the cycling state. Thus, the machine cycle time measures only the time that the machine is in motion. All cyclical machines have a configured design time and fault time. When the machine cycle exceeds the design time it is referred to as "slow" and is flagged with the SLOW CYCLE machine condition. When the machine cycle exceeds the fault time, it is referred to as an INVALID CYCLE. An invalid cycle is not treated as an actual machine condition in FIS, however. The reason for this is that in most cases, the machine will enter one of the inanimate states when the fault time is exceeded. Part Counters FIS supports two types of part counters: individual part counters and composite part counters. Individual part counters are always associated at the station level whereas composite counters are always associated at the machine level. Using a truck assembly process as an example, an individual part counter might correspond to a particular part type such as short cab, extended cab, short bed, or long bed. On the other hand, a machining operation may use an individual part counter for good parts and another counter for rejected parts. The composite counter is simply a composite representation of some or all of the individual part counters on the stations under a machine. For example, we may want the composite counter in our truck example to include all types of truck beds produced. In this case, the composite counter would be configured to represent the sum of all individual part counters. For the machining example, we may want to report only the good parts at the composite level. In this case, the composite counter would be configured such that it would include only the good part counter and exclude the reject part counter. When generating production reports, it is important that the user distinguish between individual and composite part counters.


Part counters in FIS are reported by hour and by shift. Hour and shift counts are accumulated according to the configuration of the FIS schedule. The start and end times of each hour and shift, as well as the scheduled time classification for each hour (Productive, Non-Productive, and Break) are configured in order to instruct how the production reports should be formatted. Accumulator Counters Accumulator counters are up/down counters that show the number of parts queued in an accumulation bank or conveyor. Critical threshold limits can be configured in order to flag conditions where the number of parts in the accumulator exceeds a preset maximum or minimum. Accumulator counts are archived into the historical database at ten-minute intervals. Process Variables All of the diagnostic information discussed thus far has been concerned with discrete processes. FIS also reports data from continuous processes such as tank levels and oven temperatures etc. Associated with each process variable are high limits, low limits and a set point. Like accumulators, process variable readings are archived to the historical database every 10 minutes and can be later retrieved in the form of a trend chart for any duration of time.


5 Application Navigation Once FIS is installed on a users PC it becomes integrated with the Start menu and supports features that are often seen among windowing applications. This chapter highlights some the FIS specific elements and how they are used within the Windows environment. For additional help with Windows core tasks, such as, minimizing, maximizing, and exiting applications refer to Windows Help. Running an Application To access the FIS Applications begin navigation with the Start Menu:

> All Programs > Factory Information Systems > This will produce a menu that allows entry into one of the three main functional areas of FIS; Analysis Tools, Real Time, and Tools. Selecting any one of these will display a sub-menu listing the applications associated with that function. The following figure provides an overview of the FIS applications available to the user through the menus.


FIS Analysis Tools

FIS Real Time Applications

FIS Tools

Figure 5-1 Menu Listings


FIS Application Window The FIS application features are available through windows with title, menu, and status bars. Figure 5-2 shows these components in a typical FIS application window.

Figure 5-2 Typical Application Window To best serve the specialized features of each application the bars and menu items vary across the different FIS applications. Title Bar The Title bar varies and provides FIS specific information about what is being displayed. When an application allows for the displaying of different views, the title bar will include additional information that describes that view. For example, the title bar on an FIS Graphics window, displays the name of the graphic file being used along with the plant name. A view showing a Fault/Alarm Listing has a title bar that contains different information, including the element list [*** Plant Summary ***] and the plant name Warren Truck Assembly Plant.

Title Bar

Tool bar

Status Bar

Menu bar

ACTIVE Component Window

Workspace

INACTIVE Component Window


File Open/Save Print Screen

Figure 5-3 Title Bar Examples Menu Bar FIS provides menu driven access to the features of each application. Like most Windows applications, the pop-up menus are grouped and organized by the actions that are performed. The menu items can either be accessed by clicking with a mouse interface or by using the Shortcut Keys that are displayed next to each menu item. Tool Bar The tool bar offers easy, one-click access to commonly used tasks for that application. Some of them are very simple and others will contain many more options. The tool bar is organized into groups of buttons, each group performing similarly relevant tasks. As the cursor is moved over the tool icons, the buttons function is displayed beneath it. The group of icons located at the rightmost side of the toolbar is used to launch other FIS applications quickly and easily and is found on many of the FIS applications. Only one instances of each application is allowed to be open at one time and this group makes it easy to switch back and forth between the opened applications. For example, a window is opened for FIS Graphics while the user is actively working in FIS Machine Status. Clicking on the FIS Graphics icon, will bring the FIS Graphics window to the front, where the user can continue that work session where it was last left. To go back to Machine Status, click the Machine Status icon, and the Machine Status application will be reactivated. Status Bar The status bar carries a variety of information which may also be of importance to this work session. The example below shows the contents of the status bar for FIS Machine Status. Version Local Local Plant short Message Date Time name

The version number is typically included, allowing the user to verify that the latest version is running. This is extremely useful when verifying that the application contains the latest fixes, updates and functionality. Another commonly used feature is the message area. It may contain

Launch Other FIS Apps


additional hints on how to use the application, or what is being pointed to by the cursor. The status bar can be turned off at any time by selecting Status Bar from the View menu. FIS Application Configuration Files The user has the ability to define a configuration file used to store information about window positions, machine selections, and personalized settings. The feature to save a users personal arrangement of windows and option selections, such as a machine list, is available for most of the applications. With this feature, users are able to: Arrange windows in any manner they choose and save this configuration into a file. Save personalized settings and selections for each window, using Save File. Open a saved configuration file to reload personalized selections, using Open File. Share files with other users to easily show groups of windows and machines. Use these features to create presets and default lists. There are multiple ways to access the configuration file features:

Clicking on the tool bar icons for Open, or for Save operations. Clicking on the File menu and selecting Open, Save or Save As options. Double-clicking on a configuration file or its icon directly. When this occurs the application

opens automatically with that configuration file loaded. The following table shows the Configuration file types extensions, file icons and the applications that will open automatically.

File Icon Configuration File extension

Application

.fug FIS Graphics

.fur FIS Reports

.fum FIS Machine Status

.fui FISMPI

Table 5-1 Application File Extensions


Saving a File To save a configuration file, choose Save from the file menu, or click the Disk icon on the menubar. The user will be prompted to type a filename and choose a path before saving. The default directory for your files will be the FISRW sub-directory of the installed FIS directory. . Once saved, the path and filename will appear in the title bar after FIS Machine Status.

Choosing Save will cause changes to be written to the same file. To save changes as a different file, choose Save as from the File menu and follow prompt to enter a different file name. This feature supports long filenames, and filenames with spaces.

Loading a File After entering Machine Status, opening a file can by done by selecting Open File from the File menu. The default directory for the files will be the FISRW sub-directory of the installed FIS directory. If files were saved elsewhere on the hard drive, click the drop-down directory selection to choose a different directory. Within the Windows operating system environment, double clicking on an icon will automatically open Machine Status with the contents of that configuration file. Closing a File There are a several different ways to close a file. Closing each window individually by clicking the icon in the right corner of the window,

or by choosing Close from the file menu. Choosing Close all from the file menu. Opening another file. Closing all the windows in a file renders the file itself closed. When a file is closed, its name will be removed from the title bar. File Naming Conventions FIS configuration file naming supports the use of long, multiple-word, and names with spaces.


6 FIS Real Time What Is FIS Real Time?

FIS Real Time applications allow the user to monitor the status of a machines operational state and/or its production count when. This capability helps the user to quickly identify

production problems as they occur and decrease the amount of non-productive time. The various Real Time applications are discussed in detail in the sub sections of this chapter. This section highlights User Responsibilities and explains the use of controls and parameters common to the Real Time applications. User Responsibilities In order for Machines to report properly in real time there are certain requirements the user must maintain. Standard [design] cycle time must be configured correctly in the FIS data base. Diagnostics must be maintained and accurate. Production schedules must be accurate and assigned correctly. Plant must have a designated individual for maintaining FIS integrity.

Accessing Machine Status The FIS Real Time application can be accessed a number of different ways: > Factory Information System> FIS Real Time> FIS Accumulator Monitor

FIS Cycle Time Monitor FIS Fault Alarm Monitor FIS Graphics FIS Process Variable Monitor

FIS Status and Production Monitor From any other FIS application, select the Run menu, and choose Machine Status.

From any other FIS application, press the button located on the toolbar. Double-click on a .fum file icon.


Once the user has entered any Real Time window the user may proceed directly to another Real Time application (except FIS Graphics) by selecting File then New from the Menubar.

Note that the windows are placed into groups that are relevant to their purpose. From there, they are generally referred to by level notation. Selecting a Display List A User identifies one or more machines that are to be displayed on any of the Real Time screens in the following manner. After selecting the desired application the user will be presented with a condensed list of available machines. By clicking on the desired folder the hierarchy of Department, Lines and Machines will open. When the user double clicks at the desired level all machines within the folder will be selected.

Level 1 Level 2 Level 3 Level 1 Level 2 Level 3 Level 1 Level 2 Level 3 Level 1 Level 2

Level 1 Level 2

Fault/Alarm Group

Status/Production Group

Cycle Time Group

Accumulator

Process Variable


Figure 6-1 Machine Selection Tool

Tabular or list screens can be rearranged or added to by right clicking on a row or rows. This will cause a pop-up menu to appear.

Priority Sort - When you turn the priority sort on, it will rearrange the order in which the machines are listed. The rearranged list will have the highest priority fault or alarm at the top. As events occur or clear, they will be inserted or moved to their appropriate prioritized spot. Disabling sort will not restore the list to its original order. Insert Additional Machine(s) - When you select this menu item from the right click menu it will show the machine selection screen. Machines can be selected and the machines now selected will be added to the list of the machines displayed.


Save User-Defined List - This feature saves a list of machines selected either as a local machine list or as a global machine list. If the list is saved as a local machine list it will be visible only from the workstation it was saved on. If the list is saved as global machine list it will be visible from all the workstations. User with appropriate rights can only save machine lists as global list but every FIS user can save a list as a local machine list. State Filter- You have to turn the priority sort on for this feature to be available. When you select the Set State Filter from the right click menu a selection screen will appear, displaying all the possible states. Select the states you dont want to display then press the OK key and it will filter that state. All the machines that are in the selected state wont be displayed anymore. You can undo this by turning the selected state to off.

Navigating To Other Levels and Groups

Machine Status follows two approaches to navigate to other groups and levels. To navigate to another group, while preserving the machine list, use the Copy-to toolbar buttons. See Copy-To Group. The other method is a drill down approach. This approach allows you to double-click anywhere within a component window to get to the next level. This allows you to quickly access other component windows while preserving your machine list.


Copy-To Group

The group of Copy-to icons is used to traverse between the different groups of screens while preserving the machines you have already selected. If, for example, you have a Fault/Alarm List open, and wish to view the same machines in a Cycle Time List, clicking on the Copy to Cycle Times Display will open that component window with all those machines. The copy-to buttons are level sensitive as well. If you are in a detail level screen such as Fault/Alarm Detail, and click the Copy to Cycle Times Display button, you will be taken to the Cycle Time Detail screen. Traversal options which are not available will be shown by a grayed-out button. Chart Group

The two buttons in the chart group are used for toggling between text views and chart views of certain components. The left (pie chart) button toggles between the State Monitor and the State Histogram Chart. The State Monitor component is located in the Fault/Alarm Detail and Status/Production Detail windows. The State Histogram chart displays a graphical representation of the total durations a machine was in each cycle during a shift. For more information, see State Monitor. The right (bar chart) button toggles between the Logged Event and the Event Pareto Chart. The Logged Event component is located in the Fault/Alarm Detail window.


6a Accumulator Monitor

Accumulator List This application tells the user the number of pieces in the selected accumulators and the limits as to the number of parts, maximum and minimum, that will cause a fault condition to be generated.

Figure 6a-1 Accumulator List Component The following information is presented on the Accumulator List: Column Heading Description Machine Name Description of the machine. If Show Machine Description is selected, the long name will

be shown. Accum. # A number assigned to a desired accumulator. Accum. Description A brief description of the accumulator. Actual Total amount of parts currently available in the accumulator. Abs. Min Absolute lowest amount of parts allowed in the accumulator to still perform the desired

cycle. Min Fault The lowest number of parts that will trigger a fault condition. Min Alarm The lowest number of parts that will trigger an alarm condition. Max Alarm The highest number of parts that will trigger an alarm condition. Max Fault The highest number of parts that will trigger a fault condition. Abs. Max Absolute maximum amount of parts allowed in the accumulator.

Table 6-1 Process Accumulator List Column Descriptions


Selecting Rows for Charting with Short Cut menu (Ri ght Mouse)

Single process variable charting. Double-click a single row OR- Click to select a single row, right click and select Chart.

Multiple contiguous rows. Click and drag to select a block of rows. Right click and select Chart .

Multiple non-contiguous rows. Control-click single rows in any order. Right click and select Chart .


6b FIS Cycle Time Monitor Cycle Time List The Cycle Time List component lists each cyclical machine for a given system and gives information about the duration of each cycle and other statistics related to machine cycles. When a machine cycle exceeds the standard cycle time, the cycle time turns cyan - the standard color used to indicate a slow machine condition. If the machine cycle exceeds the invalid cycle time, the cycle time turns red. The last 5 machine cycles plus the number of valid, slow and invalid cycles are shown for each row in the list. Also displayed is the total slow time, as well as the low, average and high machine cycles for the current shift. This screen is useful for determining when a machine is having consistent problems meeting a given cycle time design specification. Cycle Time List is useful for identifying causes of production bottlenecks and determining more efficient cycle times for process equipment. Figure 6b-1 below shows the Cycle Time List component.

Figure 6b-1 Cycle Time List Component


The following information is presented on the Cycle Time List: Column Heading Description MACHINE NAME A brief description of the machine. STATUS A color coded background plus short description of the current status of the machine. STD TIME The standard time in seconds for which the machine has been designed to achieve one full

cycle. INVLD TIME The time beyond which the cycle is considered to be invalid. For the most part, invalid

cycles are cycles for which a faulting condition was incurred. Invalid cycles are not used in average calculations.

CYCLE 1 CYCLE 2 CYCLE 3 CYCLE 4 CYCLE 5

The length of time, in seconds, that each of the last five cycles. (Cycles that lasted longer than the STD TIME are considered slow cycles and are highlighted in cyan. Cycles lasting longer than the INVLD TIME are highlighted in red.)

VALID CYCLES The total number of cycles in the current shift that did not exceed the invalid time. SLOW CYCLES The total number of valid cycles in the current shift that exceeded the standard time. INVALID CYCLES The total number of invalid cycles during the shift. TOTAL SLOW The total amount of time the machine has been in slow cycle for the shift. LOW CYCLE The shortest machine cycle of the shift. AVG CYCLE The average length of time for all valid cycles. (Slow cycles are included, invalid cycles are

not included in calculating this average.) HIGH CYCLE The longest valid cycle for the shift.

Table 6b-1 Cycle Time List Column Descriptions


6c FIS Fault Alarm Monitor Fault Alarm List The Fault Alarm List component is a tabular list of information relating to the current equipment status of a group of machine / stations. Current operating status is displayed for major pieces of equipment as well as a notification of the highest priority active event. This component also includes an indication of any outstanding alarms. Each row in the list represents the status of a single machine / station. The Fault / Alarm List is a real-time display, which means that changes in machine state and primary events are reflected automatically on the display without user intervention. This component supports the drill down feature, which means that a detailed breakdown of any machine in the display can be obtained by double clicking on the associated row. An example of the Fault / Alarm List component is shown in Figure 6c-1.

Figure 6c-1 Fault / Alarm List The following information is presented on the Fault/Alarm List: Column Heading Description MACHINE NAME Displays either the 15-character short name or the long machine description. STATUS The current state that the machine is in (this block is color-coded the same as the graphics

color coding for more rapid interpretation of the state). Standard color-coding convention. ALM (ALARM) A flag box to indicate an alarm condition; indicates number of outstanding alarms. FAULT/ALARM DESCRIPTION

A short description of the highest priority fault or alarm currently active for this machine.

MSG A five-digit code related to the state description associated with the message description. LOC (Location) The physical location of the faulted element or device. STA (Station) The station of the faulted element or device in multi-station machines (mostly used for

multiple stations or composite machines.) EVNTS The total number of currently active events for the machine. CMTS (Comments) A number indicating how many events have associated comments entered for the machine for

the current shift.

Table 6c-1 Fault Alarm List Column Descriptions


The Fault Alarm List Sub-Menu allows the user to alter the viewing characteristics of the display. This menu is launched by right-clicking anywhere on the screen. The following options are available on the menu: Insert Blank Row, Delete Row(s), Cut Row(s), Copy Row(s), Paste Rows, Turn Priority Sort On, Insert Additional Machines, Save User-Defined List and Set State Filter. Example: The initial screen will display all the selected machines and for some of them the current state is In Cycle. If the user doesnt want to see the machines that are In Cycle right click anywhere on the screen on the menu select Set Priority Sort On. This will rearrange the list with the machines that have the highest priority fault or alarm at the top. Now right click again and from the menu select Set State Filter a screen with all the states appears, check In Cycle and press OK button on the screen. This will hide all the machines with In Cycle state. Multiple states can be selected to be filtered. The default view for the Fault/Alarm List can be switched to a Trend view that shows the percentage of time in each state. To switch to this view select View then select Trend on the Menu bar.

Fault/Alarm List Trent View

Column Heading Description MACHINE NAME Displays either the 15-character short name or the long machine description. STATUS The current state that the machine is in (this block is color-coded the same as the graphics

color coding for more rapid interpretation of the state). Standard color-coding convention. ACC. CUR Length of time in current state. PERCENTAGE OF TIME IN STATE

Bar Chart of times in all states.

TRGT Jobs per hour rate in minutes times minutes into shift. CNT Current job count for this shift. VAR The difference between the target count and the current count. MIN Number of minutes since start of shift JPH Jobs Per Hour. The line rate, or the number of units the machine has been set to process per

hour. AVE Average Jobs Per Hour since the start of the shift. DIA Diagnostic aid for FIS. The DIA should be .1 See Formula below.

Fault/Alarm List Column Descriptions DIA Formula


6d FIS Graphics Graphics

The Graphics portion of FIS depicts the real-time status of plant floor process machinery through the use of dynamically changing text and color values.

Accessing FIS Graphics Graphics is accessed in a slightly different manner than the other Real Time Components. Since there are no parameters associated with a graphics screen and only one screen can be shown at a time the user merely highlights the desired screen than clicks OK . A double click on the desired screen description will also work. FIS organizes graphical displays into two categories: Overviews and Zoom Files.

Figure 6d-1Graphics Screen - Overviews

Plant Overview Screen Typically the Graphics application contains a Plant Overview Screen that conveys key Pay Point counts and systems statuses (Figure 6d-2). Usually this screen is divided into major areas such as in an assembly plant, Paint, Body, and TCF (Figure 6d-2). Double clicking on one of these areas will bring up an exploded view of that area (Figure 6d-3).


Figure 6d-2 Highest Level Graphic Provided by FIS Zoom Files Zoom files contain groupings of machines from a specific area or sub-area within the plant. These displays give the user a finer view of individual machine and conveyor detail. Zoom files are plant specific, and can be changed and modified upon request. The user may choose to Display Zoom Files directly by putting a in the Display Zoom Files Box. Legend Display The colors on the legend display are used to determine the status of equipment. The colors listed are plant specific. Colors will remain consistent throughout all displays within a plant FIS installation. Zoom to an Area There are two types of zooming, region or area, and actual object zooming. Zooming to an Area is commonly used to access Area Displays through the Plant Overview graphics screen. FIS is set up in some plants to allow the user to zoom in on a graphic for a more detailed look at a specific area of the plant. For example, the user may be able to z

Documents

1 Fis Users Guide v2.3