Industriesoftware

Making production transparent!inray Industriesoftware

Catalog 2017

Products and Services in industry 4.0

MES / MaintEnancE / LiMS

thE inray-principLE

Our licenses are always valid for each server license and include as many number of clients, operating pages, data points or connections. Thanks to modular licensing, our software also pays for using fewer functions. Basically our programs are open for coupling to external systems; Whenever possible, we use standard interfaces. The project development takes place on graphical surfaces and is also learnable for you as a user at any time: we train you! We – or your –create – web-based appli-cations as a complete MES-solution or as a partial solution within existing projects. Solutions are scalable: from a small manufacturing company to an international company group.

production procESS

Erp (EntErpriSE rESourcE pLanning)

opc ua/da

Data exchange with SAP systems, Dynamics NAV, proAlpha, ...

WEb-SurfacEOperation via all web-enabled devices

inray-production portaL

WEb

factory application ServerWeb-based server for MES / SCADA.Visu / HMI with faS-inMoVE

SQL

Centralized data

management

WinLaisyLaboratory Management System

opc routerCollect and distribute data

2 the inray-principle

3Making production transparent!

As one of the leading specialists for industrial software, inray has established itself in the market for MeS/SCAdA, lIMS and MdA/pdA-systems for over 20 years.Based on our own software products, we project your application to your individual requirements. Consulting, planning, implementation and training are our core-services. MDA/PDA-projects are implemented extensively from SpS to the archived report.

dAtACollect. distribute. Illustrate. evaluate.

4

FAS energy portAl

Capture, visualize and evaluate energy data. For energy management according to ISO 50001.

Index

opC router

Software-Router for automatic communication between PLCs, MES, SAP® systems, printers, Excel ... Data rotary disk for industrial 4.0 projects, universal BDE / MDE tool.

FACtory ApplICAtIon Server FAS

Web-based application server for MES / SCADA / HMI-applications.

Page 6 _______ Overview, plug-in and price listPage 8 _______ Plug-in for SAP® systems, application examples

FAS BDE modules link databases with operating / production data to the FAS. Highly flexible, they can be used to create interfaces such as cockpits and forms with displays, charts and reports.

FAS MES-modules provide basic functions of the described tasks. They can run without additional modules, but they can also be extended, for example, to FAS Web Reporting.

FAS applications are running FAS projects based on the BDE modules. The database application in the background bring it along and also provide defined interfaces. In principle, each task can be realized in this combination.

FAS-inMove

Web-based process visualization, HMI, Histories & Charts. Alarms. Pure HTML5.Data dial for industrial 4.0 projects, universal PDA- / MDA-tool.

Page 10 ______ Visualization, HMI, alarms

Page 28 ______ FAS energy portal

Page 24 ______ FAS-DashboardingPage 25 ______ HACCP-MonitoringPage 26 ______ Operating numbers/OEE

Page 20 ______ Maintenance & servicingPage 22 ______ Production planning: orders, storage, recipesPage 23 ______ Traceability

Page 16 ______ Database Modules / Web-Forms, Live-ChartingPage 18 ______ FAS Web-Reporting

Page 14 ______ Overview, module and price list

inMOVE

Energy portal

5

WInlAISy

Complete laboratory management with flexible device-connection, test-plan-based sample processing and high-operating operating comfort.

inray, inMOVE, FAS-inMOVE,FAS, WinLaisy are registered trademarks of inray Industriesoftware GmbH.Microsoft, SQL Server, Windows and Excel are trademarks or registered trademarks of the Microsoft group of companies.SAP®, R/3, SAP® NetWeaver, BAPI, ABAP, Crystal Reports, and other SAP® products and services, as well as their respective logos, are trademarks or registered trademarks of SAP® AG in Germany and other countries.Each company or product name can also be protected as a trademark without explicit labeling.All prices in the catalog are subject to statutory value-added tax.Status of product information and prices: February 2017; Errors, price and product changes are reserved.Image sources: p. 3 (picture), 6, 10 (picture), 26, 42 (picture): © industrieblick – Fotolia.com // p. 8: © branex – Fotolia.com // p. 11: © Tsiumpa – Fotolia.com // p. 14: © pressmaster – Fotolia.com // p. 21: © Kadmy – Fotolia.com // p. 23: © Benjamin Haas – Fotolia.com // p. 28: © ferkelraggae – Fotolia.com // p. 30: © motorika – Fotolia.com // p. 37 Wago // p. 41: DP Supply // p. 42: © Olivier Le Moal – Fotolia.com // p. 43: J. Tack // p. 44: Stadur // All others: inray Industriesoftware GmbH // all rights reserved, no unauthorized useinray Industriesoftware GmbH // HRB 1402 IZ // Headquarter: Schenefeld // CEO: Manfred Radtke & Sören Rose // USt-ID DE 173 507 895Holstenstraße 40 // 25560 Schenefeld // Germany // + 49 (0) 4892 890 08-0 // Fax -10 // info@inray.de // www.en.inray.de

Page 30 ______ Overview, master data, sample processing, evaluationPage 32 ______ Test plans, analysis plans, system and device integration

ControlS, opC

Page 34 ______ OPC-server/KepwarePage 36 ______ Decentralized data-collection, Wago-solutions

trAInIngS

Our licenses are unlimited. Use this: Create MDE projects, operating pages or reports yourself. We train you.

Page 38 ______ Overview, prices, training program

projeCtS

Selected reference projects from different industries and fields of application.

Page 43 ______ DP Supply: Quality assurance and laboratory managementPage 44 ______ Klingele Paper factory: Energy data managementPage 45 ______ ELE Halde-Scholven: Monitoring the wind energy systemPage 46 ______ Stadur: Machine data collection

StruCtureS

Page 40 ______ Typical system structure of inray projects

6

The industry-4.0-software

opC router

opC router

A router based on standard interfaces for automated data exchange across all automation levels.

InduStry 4.0With the OPC router, we have been providing a proven platform for years to capture, merge, and provide accurate information at the right time, in the right place. With OPC UA you use the commu-nication standard of industry 4.0. With the other plug-ins, you can integrate your systems and peripherals via standard interfaces without programming via a graphical designer.

ColleCt dAtA. dIStrIbute dAtA.ConneCt SySteMS. Typical application scenarios

process value acquisition from control systems, Storage in central database or in distributed systems (MdA / pdA)

Consumption data acquisition (material, energy) and reporting to MES, SAP® systems, energy informa-tion systems

Fault detection and status detection,Data bases for kpI, oee

recipe download from ERP / SAP® system, direct transfer to PLC or preprocessing in the MES

Component feedback /production feedback to allPlanning-/ control-systems

Collating the label data according to the requirements of the control, output on the printer

Compile data from external systems for excel- or e-mail reports

E-mail notification at acquisitionError or occurrence of certain events (supports alarming)

the opC routerAs a central communication platform, the OPC router provides automated data exchange between PLCs, databases, MES, SAP®-systems, printers, Excel ... Data transfers are triggered by time and event, there are no limits in the number of connections and transfers.

OPC Router

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G.OPC Router // Software // Basic-license and available plug-ins

your AdvAntAgeSAutomated data exchange between PLCs, databases, MES, SAP-systems, energy information systems, printers, Excel ...Gradual removal of old communication channelsSystem coupling is constantly expandableSimple modern graphical interface for connection display. History: Capture and visualize transfers and eventsAvoid redundant data collectionPlug-ins for different connection types for individual expansionConfiguration of individual connectionsIndependence: Create new connections without programming yourself. We like to train you!

OPC Router // Training >> Page 38

plug-in description price

OPC Router · Script-plug-in · XPath-plug-in

Basic license including variable, constant, scripting, data conversion · Show complex facts in C #, including individual transfer objects and triggers. · Data on X-Path-queries from XML-documents / XML code can be read out for further processing.

490 €

OPC-Plug-in · DA 3.0 · UA

Read and write OPC data points; Execute transfer: cyclic, with data change, by bit, counter (ramp bit), with limit violation // Bit acknowledgment with successful or faulty transfer, reset PLC bit.

649 €

Database-plug-in Connection of SQL-databases (MS SQL, Oracle, MySQL, Access, ODBC ...), SQL Insert, Select, Update, Delete, Execute Stored Procedures, Transfer the Result Sets // Dynamic data filters (e.g. OPC-items as query parameters). Trigger transfer when data changes or cyclically read and write XML files.

649 €

SAP®-systems Read and write BAPI, RFC and IDoc, bit feedback, RFC trigger, page 8 3.490 €

ERP-plug-in Write and receive data from ERP-systems with a Web-service-interface, call up predefined functions after integration of the WSDL-file, thereby no further programming

3.490 €

E-mail-plug-in Automatic mail-delivery, configurable templates, e.g. with OPC-items and DB-queries, variable e-mail distributors, e.g. event-dependent for alarming with escalation

350 €

Printer-Plug-in Template Designer for labels and other documents with output to Windows-printers 990 €

Microsoft Excel Create or update Excel tables, for example, for daily reports 649 €

WS-plug-in Weihenstephaner Standard: MES ERP interface for the beverage- and food-industry 2.990 €

Euromap 63 Read and write data according to Euromap-63 standard 2.990 €

Euromap 77 Data exchange for industry 4.0-projects according to Euromap-77-standard 2.990 €

Charm-EZ-plug-in Coupling with the Charm-EZ-Reader (inhibitor rapid test in the dairy industry) and/or the Charm-EZ-M-Reader (Screening Mykotoxine) to transfer new analysis values to the laboratory system or control system.

649 €

OPC

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Plug-in for SAP®-systems

CoMplete IntegrAtIon oF SAp®- SySteMSThe OPC router plug-in for SAP®-systems opens the door to the world's most frequently used ERP-system. The connection is made at the production site via the database plug-in or via the OPC plug-in directly to the PLCs, on the SAP® side via the standard interface BAPI, direct RFC call or via IDocs. The OPC router connects your entire pro-duction network to the SAP®-system. Without programming. The module used is certified as "SAP® Certified Inte-gration with SAP® NetWeaver".

your AdvAntAgeScomplete SAP® integration of production without programmingsynchronous communication enables "conversation" between SAP® system and PLC (BAPI)no limit in the number of data points and connectionsTransfer-call also from SAP®-system via RFC

Other ERP-systems are to be integrated (Dynamics NAV, proAlpha, Oracle …) depending on the interface, via the database or the ERP-plug-in.

SAp® Certifi ed Integration

with SAp® netWeaver®*

CouplIng WIth SAp® SySteMSfor example

download of production-orders and -recipes into the production database or directly to the PLC.

Storage location requests from the PLC, releases and transport orders from SAP® system in response.

Production confi rmation by PLC, booking confirmation by SAP® system.

Consumption reports and daily material status notifi cation (with automatic recording without manual intervention)

In/out storage releases and orders

process data acquisition

Connection of energy meters

opC router

A standard interface-based router for auto-mated data exchange across all automation levels.

OPC Router

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s.OPC Router // Software // Plug-in for SAP®-Systems

exCel-reportIngReading the current data from the PDA-database // Writing the data into an Excel-template with predefined tables and charts // Current file is always at the same place // Archiving older files // Implemented with Excel-, OPC- and database-plug-in

generAtIng trAnSport orderS In the SAp®-SySteMPLC reports a pallet for storage by bit // OPC router transfers palette data to the res-ponsible BAPI-method // SAP®-system issues a storage request after checking data // realized with OPC and SAP®-plug-in

event-drIven e-MAIlSAlarming for limit value violation // Monitoring of relevant process values in the PLC // In case of limit violation: triggering the e-mail with process value, time stamp and working instruction // realized with OPC and e-mail plug-in

lAbel prIntIngGraphical label designer // Variables are filled at operating time // Output to installed printers // Labels with text, barcode, images, graphical elements // Dynamic printer selection during operating time

Coupling Systems & Distributing Data – Application Examples

OPC

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10 FAS-inMove – visualization without limitsPages, tags & clients license-free

FAS-inMoveFrom any web-enabled device – in addition to the office PC, including smartphones or tablets – you access your process visualization via browser, see actual values, charts with histories and alarms. With appropriate user rights you can operate the system logged.

WebvISuAlISIerung

Prozessvisualisierung mit Historienauf-zeichnung, Alarmierung und Bedienung. Keine Browser-Plug-ins – 100 % Web!

leIStungMachine data recordingCalculationsSystem visualizationDisplay of actual valuesHistories in live chart including Gantt-bars

Alarms via website, desktop and e-mailFlexible user management with free definable groups/rolesMultilingualismAudit trail: logged operations

FAS-inMOVE

inMOVE

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FAS-inMOVE // Process visualization

Operation & Monitoring – from everywhere

operAtIon And MonItorIng100% pure HTML5 representation: Pure web without plug-ins like Flash or SilverlightDisplay on all web-enabled media: From the smartphone via desktop to a large info displayLive-View: Charting and actual-value displays are automatically updated whith new values. Without page refresh.Alert occurs – next to the e-mail – via the FAS-inMOVE visualization and, optionally, as a pop-up notification on the desktopAccess control for control elements (switches etc.) via user management and security tokens

one Server lICenSe. no lIMItS.No limitation in the number of OPC-connections (PLCs), data points and histories, user pages (attachments), users and clients.

FAS-

inM

OVE

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FAS-inMOVE functionalities

Definition of data points. Import of entire OPC-tree-structures or individual branches, import of Siemens-PDF. Record as history or live data point. Flexible recording criteria. Processing of large data point lists via Excel.

Calculated data points. Formula-editor for configuring calculated data points, for example, the sum of several data points. Function library, for example, for trigonometric functions or complex if-then queries.

Chart-layout. Definition of layouts for individual histories such as color, value-range, Gantt bar. The settings are suggestions, which can be changed for each individual chart image, also by the operator at operation-time.

Alarms. Flexible alerting with escalation strategy via e-mail list, message in the Visu and desktop notification. Criteria are limit-value-violation, status or mes-sage-bit-categorization of the messages and acknowledgment with comment.

Multilingualism. FAS-inMOVE reads the words and phrases used in your projects automatically. You translate into any desired target-language.

Connection of opC servers. FAS-inMOVE supports the OPC-standard and has no limit in the number of OPC-servers. Local or remote – DA or UA.

FAS inMOVE wizard will guide you through the setup of data acquisition and alarm definition. After the installation, it takes only a few minutes for the system to record the first data.

Web vISuAlIzAtIon

Process visualization with history recording, alarming and system operation.

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FAS-inMOVE

inMOVE

Audit trail. Operator actions for the PLCs are logged. The entries can be accessed at any time on the FAS-inMOVE server. They can be grouped, sorted or filtered and can be exported to Excel format.

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FAS-inMOVE Designer

FAS-inMOVE // Process visualization

prICeFAS-inMOVE Server license 2.990 €Additionally required: Database server, OPC server // MS SQL Server Express (free license), demo version of the OPC server KEPServerEX for simulation and test are included. Paid upgrades are available at inray.

WhAt you See IS WhAt you getIn the graphical FAS-Designer you can combine your process visualization with finished elements. Your start-project already contains current-value- and alarm-lists, live-charting and user administration. Add additional pages easily – without limits in the number of pages, installation graph, or data points:

Import installation graph Set controlsSelect data points to be visualizedSave. Publish. Operation and monitoring

Just as easy you can convert cockpit pages: With additional charts, data lists, tachograph displays, circular diagrams, progress bar ...

So simple: Import installation graph, place controls, assign data points.

FAS-inMOVE // Training >> Page 38

FAS-

inM

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14 Factory Application Server FASOne Production portal – 100 % Web

All MeS ApplICAtIonS on one portAl

Your production portal unites all MES applications or projects on a unified web interface. Access is by individual authorization via a web browser – from any computer, smartphone or tablet, without installation, without client licen-se.The production portal generates the required information from the available data – also from external systems – and presents it clearly. And tailored to your needs. At the right time, in the right place. Pure HTML5, without browser plug-ins. Industry 4.0 to measure.

Data collection,Charts,Web-ReportingPage 16 onwards

Maintenance and repairPage 20 onwards

Production planning Page 22 onwards

Trace /TraceabilityPage 23

FAS-Dashboard Page 24

HACCP-MonitoringPage 25

Key figures /KPI / OEEPage 26 onwards

Energy managementPage 28 onwards

FAS

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Factory Application Server // Software // Basic License

your AdvAntAgeSA server installation, not a client installationGradual introduction possibleScalability ensures investment protection: FAS grows with your requirementsData exchange with external systems for efficient data useEconomically, thanks to modular licensing, even when using fewer functionsUse as a complete MES or to complement existing systemsMultilingualism: Flexible translation of the surfacesNo limitation in the number of application pages, data accesses, clients, and users

FAS // Training >> Page 38

Module description price

FASFAS DesignerDatabase-module – Page 16

Basic license, OPC Connect, user administration, language module, graphical designer for creating the application pages, in basic licenseInput (web forms), display, calculation, execution of stored procedures,Filter, export, import for all database-based applications such as OEE, cockpit, PDA, monitoring

2.900 €

Live Charting – Page 17 Display of historical values in the diagram, live mode: Chart runs in real time 1.200 €

FAS Web-Reporting – Page 18with report dispatch

Creation of comprehensive reports with minimal effort directly via the graphical FAS web interface (HTML5) – Without programming // Access to any available data source and integration with wizards, barcode-generation and export to PDF, Word, Excel, RTF possible, subreports via drag and drop, chart creation and comfortable data grouping, analysis of detailed data, automatic report sending via e-mail, to the file system with individual scheduling

2.900 €

Maintenance module – Page 20

Maintenance Management: Scheduling, Order Distribution, Acknowledgment, DocumentationSpare parts storage management

2.500 €1.200 €

Order management – Page 22 Production planning in detail 2.500 €

Recipe management – Page 22 Management of production recipes, coupling to orders and stock 2.500 €

Stock management – Page 22 Complete material management including reservations, releases,Traceability

2.500 €

Traceability – Page 23 Traceability 2.500 €

FAS

16 FAS database-moduleWeb-forms and live-ads

teChnICAl SpeCIFICAtIonSConnection of SQL-enabled data base systemsOne module-license, any number of systemsFAS-internal data views can be configured – e.g. for data filters and sorting criteriaTriggering of stored procedures with parameter transfer and processing of the resultsUpload/Download in Excel-FormatBasis of complete web-user- interfaces, also for existing database applications

ApplICAtIon

Web-ForMS: ColleCt dAtA, pAperleSS WorkFloWWhenever information is delivered on paper from workplace to workplace, the data-base module is suitable: A FAS page for data input and display is quickly configured. Once recorded, the data is available to all workstations and serve as a basis for reports or charts.

dAtA dISplAyAll the elements for data display access the database via the module: individual valu-es, lists, status records, progress bar, Gauges, XY-Charts ... The displays are automatically updated when the data is changed ("live display") e.g. according to calculations in the database, modification of filter criteria (PLC data!), Data transfer from external systems.

MdA/pdA-ModuleS

PDA-modules conect database-applications to the FAS.We – or yourself – develop custom-made MES-projects.

FAS DBM

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Factory Application Server // Software // Database/Web-forms and Live Charting

teChnICAl SpeCIFICAtIonSFree connection of SQL-based database systemsMinimum requirement for data tables (value, time stamp)Definition of multiple-use data sources (measured value series) with layout templatesSorting the data sources into existing hierarchies (topology, master data structure)Chart export in PDF- and Crystal- format, data export in Excel-FormatStatistical calculations for current valuesForm eleditor with function-libraryData grouping to display average, minimum, maximum ...

FAS live ChartingMonitoring and analyzing processes

ApplICAtIonThe FAS Live Charting presents historical data in the diagram – from a simple curve to points, columns, surfaces up to the Gantt bar. The display is also free configurable for the operator. Restriction of time periods (batch selection, batch comparison), period comparison, point-accurate value display and zoom are self-evident. In live mode, the chart runs in real-time and updates as new data are available.

MAxIMuM FlexIbIlItyData can be collected from different databases. Reusable layout templates and free text/color assignments for Gantt bars. Individual templates are also available for exports. The operator has the possibility to connect and disconnect data sources – even during operation time. Personal configurations can be saved.

FAS // Training >> Page 38

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CreAte reportS – quICkly And eASIlyReliable reporting is an indispensable tool in any company. FAS Reporting allows the creation of comprehensive reports with minimal effort directly via FAS web interface – you don't need any programming skills.You can easily select the desired report layout from the graphical interface in the FAS, using drag & drop and set the query criteria. Comprehensive integrations for individual requirements can easily be presented themselves – and can also be changed during operation-time. The data of your centralized, uniform reporting system is always up-to-date and can be queried on mobile devices.

teChnICAl SpeCIFICAtIonS Creation of own reports via the web interface in FAS – 100% webbased (HTML5) – without programming Access to any available data source (e.g. FAS-inMOVE, FAS Views, stored procedures, Live Chart) and integration via wizard Create charts with independent data sources Comfortable data grouping via wizard Automatic grouping of the x-axis in the chart possible, e.g. after months or years Barcode-generation possible

FAS Web-reporting Reporting – directly in the browser

FAS Web-Reporting

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doCuMentAtIon dIgItAlView process value traces, key figures, evaluations or audit-relevant documentation, trends and statistics from the various production sections, such as maintenance, HACCP, energy management, traceability ... FAS Web Reporting allows you an optional Access management and allows export to various formats.

teChnICAl SpeCIFICAtIonSSubreports – simple integration via drag & drop and entry of the query criteriaSecurity: Access rights can be transferred from the user administrationNo admin dial up required to create new reportsParameters can be changed during operation-timeExport to PDF, Word, Excel, HTML or RTF possibleActual reports: Always up to date with the latest dataAnalysis of detailed data (drill-down)

Factory Application Server // Software // FAS Web-Reporting

FAS Reporting // Training >> Page 38

FAS

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SCheduled reportIng – report ShIppIngControl Scheduled Reporting allows new reports to be added or modified for regular dispatching. Convenient report sending with freely definable recipient lists and selec-table shipping interval. Different shipping modes are possible as well as the capture of one's own additional E-mail text.

20 Maintenance and repairMaintenance Management with FAS

ApplICAtIon

Core ApplICAtIon: MAIntenAnCe ModuleYou use the maintenance module to schedule maintenance operations and accept the acknowledgment after the maintenance process has been completed. You can organize the components of your systems flexibly, assign tasks to employees or employee groups. Maintenance types are freely defined, instructions and technical data sheets are included. Employees acknowledge the maintenance, including the working time, and arrange further operations if necessary. The collected data serve as a basis for the proofs and audits.

expAnSIon: SpAre pArtS Store, AudItAble doCuMentAtIon, AlArMWith the FAS modules for spare parts storage, reporting and ScheduledReporting and the OPC router extend the core functions to a complete maintenance management system including auditable maintenance documentation and optimiza-tion processes (downtime minimization by maintenance bundling).

opC router: CouplIng externAl SySteMSData transfer from external systems, e.g. building management // Coupling with ERP-systems (e.g. SAP®-systems) // Monitoring and recording relevant machine data (switching games) // Monitoring the maintenance data and alerting the control system in the case of omissions // Shipping of notifications

MeS-ModuleS

In principle, MES modules can operate without further modules / configuration and provide basic functions for the described tasks.

FAS Maintenance

Maintenance & repair

Documents Certificates Maintenance module

Electrical- & mechanical

maintenance

Reportscurriculum vitae,

maintenance, hour evaluation

Spare PartsMaintenance plans

System

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Factory Application Server // MES-Modules // Maintenance & repair

teChnICAl SpeCIFICAtIonS

Core applicationHierarchical display of the systems and componentsIntegration in existing master data structureSchedulingDynamic recalculation after operating breaksInformation of the employees to upcoming maintenanceFree definition of maintenance typesAssemble the necessary documents such as order, instructions, safety data sheetsAccept the acknowledgmentPermanent storage of the data

teChnICAl SpeCIFICAtIonS/optIonS

Scheduling according to machine conditionsE.g. switching games, number of piecesNotification of employees / external companies by e-mail with order and relevant documentsSpare parts storage management With base data, stocks, booking via mobile devices (e.g. by barcode scan)Automatic order or request to the purchasing departmentSupport for auditsLabeling of relevant processes (e.g. for BGV, RÖV, HACCP, energy monitoring)Documented report release, digital archive of signed reportsAutomatic shipping to different receiver circuitsAlarmingNotification of employees at maturities, absence of maintenance or generally critical conditionsEscalation strategyAdjust to the individual componentConfiguration also by administrator during operation time

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22 FAS recipes / orders / stockModules for production planning

FAS reCIpeSThe core tasks of the recipe management are the creation of recipe structures andRe-cipes, their logged changes and the control of externally loaded recipes. With the help of the production recipes, the system checks during the planning, in conjunction with or-der- and warehouse management, whether the required raw materials are available. The module provides the recipes for download to the controls – the actual recipe manage-ment remains in the control system. You can use this module not only for production, but also for cleaning processes (CIP).

Structured recipes (Master / Subscriptions)Step Recipes Transfer to the controls (Via order management)Cascading version control (Output versions are retained)Recipe structures freely configurableStorage of all recipes and versions in database, loading the current version into the control

FAS StoCkThe storage module ensures a smooth exchange of information between storage and production. On basis of order- and recipe-data, the raw materials are reserved and are thus blocked for other batches. The management of the materials is batch-rela-ted, taking into account of the storage location type. All bookings are documented and traceability is supported accordingly.

Booking of storage and retrieval via bar code or manual inputRebookings and phantom-bookingsMaterial reservationConsumption booking after PLC-confirmationManual locks and release batch management according to storage-location-types (e.g. "tank" = "batch mixture")Release according to criteria such as batch, line, priorityContainer availability check, automatic log-on and log-off for system-supportCoupling with conveyor technology possibleBase data-managementBooking history for traceability

FAS orderSThe order management coordinates the production: After receipt of the order data (by transfer or input), the module determines the possible batch sizes based on the recipes and inventories. Available materials are reserved, recipe and header data are transferred to the PLC.

Determination of possible batch sizesSet of quantitiesResidual quantity processingCyclic header file transfer (configurable)Recipe transmission to the PLCMaterial reservationPlanning by production linesConnection of external systems possible (optional configuration), for example, production orders from SAP® systems

MeS-Module

In principle, MES-modules can operate without further modules / configuration and provide basic functions for the described tasks.

FAS Planning

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Factory Application Server // MES-Module // Production Planning, Traceability

FAS traceabilityTarget tracking

ApplICAtIonSeamless traceability of all materials, raw- and finished-products: FAS Traceability reports to you, what, when, where and how is processed. You can select raw mate-rial, intermediate or final product interactively and see all upstream and downstream processing-stages across the entire process chain. Live on web or optional as a PDF-report.

teChnICAl SpeCIFICAtIonSReady-to-use, database-supported moduleDefined PLC-interface to transfer the required dataBatch data are available live, immediately after takeoverInterface to QS-systems (LIMS, HACCP ...) for corresponding batchesGraphical representation of the process chain with customer- specific entry pointsAnalysis from each processing-unit forward or backward to the beginning and end of the chain

FAS

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ApplICAtIonWith the FAS dashboard, you can create your own reports so that your employees can keep track of their most important data at all times. With a graphical Designer on the FAS interface, cockpit pages can be customized. Links lead to bases with corres-ponding detailed information. This enables you to visualize, for example, key figures (OEE), consumptions, faults, pending orders, states of plants and components ... This allows you to keep track of your important data at any time, and you are able to react quickly to incidents at any time.

teChnICAl SpeCIFICAtIonSComfortable creation of a dashboard via graphical designerPages update automatically – without user interventionAccess to all data sources that are created in the Web reportDetailed information by selecting individual actions or group selectionpossibilities to filter data can be configured itselfAn adjustable time beam can be used to limit information accordinglyUser administrationIndividual start pages for different user groupsResponsive WebdesignDrill-down navigation for viewing data in layers

FAS dashboardMonitor projects with individual cockpit

ApplICAtIon

Dashboard is adapted to an existing or new data base and grows with your requirements.

FAS Dashboard

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Factory Application Server // Application // Cockpit, HACCP

Automate hACCp monitoringSave quality and save paper

ApplICAtIonThe monitoring according to HACCP or similar concepts (FMEA) is individually tailored to your production and used wherever PLCs monitor critical steering points and automatically take action in case of limit violations. FAS HACCP records the reported values and imple-mented measures and thus fulfills the requirements of a gapless documentati-on. Data can be called up at any time, for example, on the chart or displayed as a report. Optionally is the report release of all errors and corrections, for example, done by the shift manager. Reports can then be digitally archived. HACCP on the state of the art!

teChnICAl SpeCIFICAtIonSTransfer and storage of all HACCP- relevant data from the PLC to the BDE-systemMonitoring in live chart and facility visualization as requiredAlarmData- and report-releasesTabular reports about all errors and actions, graphical reports with value historiesOptional: Coupling with maintenance-module for scheduling and documentation of validations

HACC

P

26 Collect data and calculate oeeThe way to the key figure

eFFeCtIveneSS

quAlIty rAte

Interruption (broken down by category), set-up time

Good-amount produced amount

AvAIlAbIlIty

Main usage time Scheduling occupancy

period

Loss of performance

Calendar time: 24 hours × 7 days

Error-free output Time loss

produced amount × target cycle

Speed drop, smaller standstill

Target cycle: planned production time per unit

produced amount

good-amount

Quality loss

waste, start-up losses, restoring work

oee – overAll equIpMent eFFeCtIveneSS = AvAIlAbIlIty × eFFeCtIveneSS × quAlIty rAte

In the planning time the maximum possible quantity

Quantity × target stroke

Main usage time

Scheduling occupancy period

Main usage time

Planned shutdown

Planned shutdown

Time loss

Loss of performance

Quality loss=

=

=

The Overall Equipment Effectiveness (OEE) measures the actual effectiveness of a system by setting the error-free out-put quantity in relation to the maximum possible quantity. Further KPIs such as throughput, degree of set up or occu-pancy (capacity) can also be calculated on the basis of the once recorded data and are currently available.

OEE

Such as weekend, annual work holidays, routine maintenance

27

ApplICAtIonFAS applications are ready-to-use MDE / BDE projects, which however can be adapted to your requirements in a highly flexible manner.

Factory Application Server // Application // Key figures (KPI/OEE)

your AdvAntAgeSKey figures are virtually available in real timeKey figures are available for free definable periodsReports can be freely parameterized (key figures by periods, products, lines ...)Fine drill-down analysis on individual disturbances, waste numbers ...No limits in the number of controls, Visu pages, reports

teChnICAl SpeCIFICAtIonSCentral data storage and ongoing calculation of the key figuresDetection of necessary data from all sources, e.g. cycle- and disturbance- time from PLC, malfunctions after acknowledgment by touch panel, booking of batch quantities by barcode scan or manual inputDefined PLC interface, adaptations optionalOptional: Distribution of the processed data to other systems

ApplICAtIonIn your individually created web application you will see the current performance figures of your plant – by shift, order, line, product ... The live-display allows you to react quickly to deviations. Reports for detailed analysis are called immediately after the data are available, for example, to evaluate the shift immediately after its end.

OEE

28 inray-energy portalVisualize and monitor the energy consumption

ApplICAtIonWith the FAS-energy portal from inray, you have a clear view of all consumptions: plant, company, groupwide. Smooth recording, invoicing, current display. On every scale. Quickly and easily via web-browser.

energy portAl

Capture and visualization of the energy consumption. In addition, all FAS-inMOVE functions (process-visualization) are included.

perForMAnCe FeAtureSIndividual web cockpit with updates from counters and databasesLive charts with graph and Gantt bars, period comparison and value displayMaterial- and energy-flows in a Sankey diagramCreation of comprehensive reports with minimal effort directly via FAS web- interface. Comparisons of periods, target / actual comparisons, success control of procedural measures, Report shippingE-mail alert (with escalation) with free definable criteriaDocument management for operating- and maintenance-manuals, network ...Integration into existing company hierarchy / topologyAnchor-Resizing: All pages fit automatically to page size

plAn – do – CheCk – ACtThe monitoring of the resource-con-sumption is an important part of the energy portal according to ISO 50001. Live-monitoring in the cockpit and aler-ting enable fast response; detailed re-porting serves as a basis for long-term-analysis and success control of energy saving measures.

Plan Do

Act Check

Energy

energy portal

29

Factory Application Server // Application // Energy portal

IndependenCe: StAy AS FlexIble AS poSSIbleYou can monitor your consumption via a PC, tablet or smartphone - no installation, the web browser is enough. The creati-on of new counters, the configuration of reports or histories in a chart takes place interactively via a web interface: Get your personal monitoring with a few clicks. All participating systems communicate manufacturer-independent via standard interfaces, e.g. via OPC for connecting PLCs (Siemens, Wago ...) or measuring devices (Janitza, Schneider, Socomec ...).

energy MonItorIngCollection of consumption types with free subdivision, e.g. electricity, compressed air, cold, heat (gas, oil), waterEasy connection of measuring devices / PLC data points via wizardTransfer of production data to calculate specific consumption indicators (by article, product group, periods ...)Configuration and monitoring of energy saving measures to reduce consumption / costs / CO2 emissionsCalculated data points: Formeleditor for the calculation of data points (e.g. for the EnPI-calculation)Logical summary of physical meters / measuring points (e.g. cost allocation, evaluation by department, plant groups ...)Rates for meters can be set individuallyIn addition: manual entry of counter values from devices without connectionFree definition of indicators (Energy Performance Indicators EnPI)The control "Advanced Grid" allows simple filtering / search / grouping

Independent of manufacturer by open standard interfacesConsumption monitoring in the context of ISO 50001100 % Web: Access from the PC, Tablet, Smartphone ...One server license, data points / tags and clients licence-freem

aste

r pag

e

prICeFAS-energyportal 8.200 €contains FAS-inMOVE, energy portal and OPC driver (KEPServerEX), FAS Web-Reporting. Additionally required: Database server, possibly further OPC-drivers. MS SQL ServerExpress (free license) included, charged upgrade via inray available.

mas

ter p

age

Energy portal // Training >> Page 38

Ener

gy

30 WinlaisyEffective laboratory management

teChnICAl SpeCIFICAtIonSComplete laboratory system with uniform data storage for the entire laboratoryInterfaces to external systems (PLCs, MES, ERP ...)Connection of analyzers for automatic data transferCentral master-data administration with flexible test-plan-designSample processing with audit trailAutomatic preparation of assayIndividual evaluation jobsSearch function over all columns with color markingsComfortable groupings and nesting over tablesAdministration of different versions – even old versions can be activated (including history and approval process)

The powerful LIMS WinLaisy makes your laboratory administration and documen-tation simple and effective: from any Windows desktop you have access the master data, process samples and start evaluations. The clear interface offers you a com-fortable operation with the graphical designer. Thanks to open program interfaces WinLaisy integrates numerous laboratory and peripheral devices – the system is commissioned by us and adapted to your laboratory equipment. If necessary, we can also set up a web portal to monitor evaluations, reports and assay requests at any time on all web devices and to collect mobile data.

WInlAISy

Complete laboratory management with individual device connection and high user comfort for fast manual data input.

WinLaisy

31

prICeSWinLaisy allows a variety of configura-tions (lab and production peripherals, data exports and imports). We will therefore make an offer on your request.

WinLaisy // Software // Server and Clients

MASter dAtA MAnAgeMentDefinition of analysis groups and analyzes (test methods)Definition of product groups, products and articles with flexible criteria for identification / traceabilityBarcode labels for sample identificationTest plans – Summary of several analyzes with warning and limit values for the release consideration of individual productsRights / Users: Free assignment of the WinLaisy functions to user levels, rights management can be individually configured

SAMple proCeSSIngAutomatic generation of samples based on the test plansCreating and editing the samples, entering or taking over the results and evaluationAudit trail (central change history)Add further analyzes / test plans in addition to the specificationconnections of samples e.g. during testsCustomized (even multi-level) filters possible

Manual sample input (top): Optimized for fast processingEvaluation (right): WinLaisy-internal tabular overview

WinLaisy // Trainings >> Page 38

Win

Lais

y

evAluAtIonSIndividually defined layouts and evaluation jobsTest reportsQuick overviewStatisticsData exportEvaluation directly in Excel templatedistorsions statisticsMail deliveryExport to other systems (Felix, SAP®)

32

teSt plAnSTest plans are a central WinLaisy-com-ponent. They serve as a template for sampling and analysis.

test plans …summarize all necessary analyzes for a particular productknow where the data comes from (analyzer or manual input)contain product-related warning and limit values for each analysispropose the corresponding assessmentknow which barcode labels are needed

When a sample is created for a product, the stored inspection plan therefore ini-tiates all necessary processes. Flexibility is maintained: Complementary analyzes are possible for each individual sample.

AnAlySIS plAnSAnalysis plans control analysis cyc-les and minimize analyzes in selected processing stages.

Analysis plans …control how often individual analyzes are carried out over the test planlimit the investigation of individual parameters in a sample seriescan be assigned to individual processing stages

Taking into account the test plan, different samples with the required analyzes are generated automatically for a sample series.

WInlAISy

Complete laboratory management with individual device connection and high operating convenience for fast manual data input.

Inspection plan (left) and analysis plan (right) define analyzes and their frequencies

WinLaisy

33

WinLaisy // Software // System integration

SySteM IntegrAtIonoptIonAl ModuleSConnection / data transfer vehicle balancetransfer the values of data- transmitting devices (eg FT1, FT120, MS133, FoodScan, Lactoscope, etc.)Transfer of values from system controls (PLC)Production data acquisition and its takeover in WinLaisyInterface to the FAS: Integration of FAS pages with laboratory-relevant data from the BDE, e.g. for sample preparation from the MES.

lIve MonItorIng oF AnAlyzeSIndependent data storage (SQL) also al-lows third-party systems access to the analyzes. For example, if you use the Fac-tory Application Server for visualization and production monitoring, you can read the current results from automatically performed and recorded analyzes. These results are included as a value display or list in the production visualization. Trace systems can also be coupled with WinLaisy.

External access via web interface: access to current samples or prints of analysis reports and certificates.

Win

Lais

y

34

The powerful OPC server from Kepware (KEPServerEX) offers drivers for more than 150 different controllers with all possibilities to realize your OPC networking. Kepware OPC servers provide the reliable data base for your industrial 4.0 projects via the OPC UA interface. Via REST and MQTT you couple the Internet of Things.

drIverS AvAIlAble ForABB Totalflow, Allen-Bradley, Alstom, Analog Devices, Aromat, AutomationDirect, BACnet, Beckhoff, Bristol, Busware, Contrex, Cutler-Hammer, Dataforth, DDE, DNP, Enron Modbus, Fanuc, Fisher ROC, Fuji Flex, GE, Hilscher, Honeywell, IA Super SEL, Idec, IEC 61850 MMS, Intelligent Actuator, IOTech PointScan, Krauss Maffei, Lufkin Modbus, Mettler Toledo, Micro-DCI, Mitsubishi, Modbus Serial/Ethernet, MT Connect, Omni Flow, Omron, OPC DA, OPC UA, OPC XML, Optimation OptiLogic, Opto 22, Partlow ASCII, Philips, Sattbus, Scanivalve, Siemens, Sixnet, SNMP (Network Management), SquareD, Telemecanique Uni-Telway, Thermo Westronics, TIWAY, Torque Tool (Atlas Copco), Toshiba, Toyopuc, Triconex, Wago, Weather-ford, WITS Level 0, Wonderware InTouch, Yaskawa, Yokogawa

kepServerex OPC server and communication-platform

As Windows service configurableConfiguration can be changed during operation timeCommunication via Ethernet and serial-connectionsCSV import and export of the symbol configurationDetailed logging, configurableDrivers for network- and system-monitoringbuilt up modular: only license what is needed

Kepware

OPERATIONS MANAGEMENT PREDICTIVE MAINTENANCE

ENTERPRISE INTELLIGENCE

MEASUREMENT

PACKAGING

IT / NETWORK

FACILITIES MANAGEMENTPOWER & UTILITIES

MANUFACTURING

OIL & GAS

PROCESS MANAGEMENT

CONTROL

35

opC tunnel WIth kepWAreAn OPC tunnel can be implemented between two instances of the KEPServerEX.The systems are coupled via OPC UA plug-in and OPC UA client-drivers.

OPC communication in the network with TCP / IP also via firewallsUpgrading to OPC UA, avoiding DCOM problemsConnection of OPC clients and servers of older specificationsEncrypted communication in distributed systemsOPC client / server redundancyControlled provision of definable data pointsDisplacement of the computer utilization to newer systems possible

OPC servers and controllers // Partner products // Kepware

Inray is Kepware's Preferred Distributor for Germany: licenses, training, support – all from a single source.

KEPServerEX // Training >> Page 38

Via the plug-ins (orange), KEPServerEX provides the data not only to OPC clients but also, for example:Network monitoring systems (SNMP)Splunk (big data analysis)

prICeSPrices depend on the dollar rates. Please ask for current prices.

Preferred Distributor

Iot – Internet of thingsThe goal of the Internet of Things (IoT) is to connect the information from the real world and the virtual world and to implement intelligent automation.The KEPServerEX provides an IoT gateway that connects automation to Internet / cloud-based software systems. The IoT interfaces REST and MQTT are supported.

Kepw

are

APPLICATIONS

DATA SOURCES

OPC, MQTT, REST, EFM, ODBC, NATIVE CLIENT, SNMP

PLC, OPC CLIENT, RTU, DATABASE, CUSTOM

INTERFACES

DRIVERS

SERVER

PLC RTU / FLOW COMPUTER

DATABASE/APPLICATION

SENSOR & ACTUATOR

OPC SERVER

DATABASEBIG DATA/ANALYTICS MEASUREMENTHMI/SCADA MES/HISTORIAN ERP

ADVANCEDFUNCTIONS

TUNNELING

SECURITY

TAG LINKING& LOGIC

SCHEDULING

DATABASELOGGING

MACHINE-TO-MACHINE

REST Server REST Client MQTT Client ThingWorx®

MicrosoftAPIs

IoT API

Scheduling

Analytics

Modeling

Connectivity

Big Data/Analytics

36

FroM the SenSor to the netWorkWago controllers enable machines and operators to capture the necessary ope-rating data. They also serve as transdu-cers for counters and measuring probes, process the data and pass them on to the OPC server. Erroneously, elaborate manual reading becomes superfluous. In BDE projects, we supplement existing structures with the necessary hardware including programming and commissio-ning. In doing so, we pay particular atten-tion to the reliable interplay of the com-ponents in order to prevent data loss.

WAgo Controller In uSeConnection of energy meters to large-scale consumersCombine of small consumers in groupsDetection of application quantities of individual linesCompilation of interruption-times and -reasons by componentsRecording of process values and audit-relevant data for quality control Decentralized performance monitoring, determination of the basis for key figure calculationOPC UA Server is integrated (from PFC 100 / PFC 200)

decentralized data collectionBDE-solutions with Wago

inray Industriesoftware is…W

ago

37

OPC servers and controllers // Partner products // Wago

Performance and energy measurement

InStAllAtIon SCheMeThe individual conductors are equipped with current transformers, eg in the switch cabinet. The 855 series trans-formers can be retrofitted without in-terrupting the current flow. One current transformer is required per phase. The terminal block (eg 2007-8873) in the upper right corner of the picture provi-des easy connections for the convertor (picture.) and voltage. The transfor-mers can be short-circuited (e.g. when the measuring clamp is removed). The connected power measuring clamp 750-494 calculates, among other things, the energy consumption, active-, apparent- and reactive-power. Via the 750-881 Ethernet controller, the results are available for the control- and evalua-tion-systems (FAS energy portal).

non-binding prices

description order number price

Programmable Ethernet Controller (PFC 100) 750-8100 333,00 €

Serial interface RS232 / RS485 750-652 200,80 €

3-phase power measuring clamp 750-494 169,00 €

8-channel digital input terminal 750-430 39,78 €

Bus end clamp 750-600 9,65 €

Power supply / power adapter 787-1002 75,83 €

Cable-Reconstitution-Transformer 855-3001/0060-003 72,00 €

Terminal block for current transformer circuit 2007-8873 87,59 €

Wag

o

38 System structure

External systems via web-services

ERP / SAP-systems

Process values, statistics, alarms by e-mail

Excel-Reporting

SQL-based foreign systems

Printers, label printers, price markers

opC router

Systems with integrated OPC-UA-server

Other OPC-serversDA/UA/XML

Further open and proprietary protocols

kepServerex

Wago

Janitza

Siemens S7, S5

Over 150 other protocols

SAP®

@

39

StruCtureSTypical structure of inray projects: The OPC router on the left assumes the complete system integration from the PLC to the SAP®-system as well as the addressing of external devices such as printers or price markers.The FAS (right-hand side) provides the MES / SCADA / HMI functionalities and can be accessed via any Web-enabled device.The quality assurance is directly linked via the shared data storage with the WinLaisy laboratory system.

inray // System structure

Sql Server Factory Application Server

lIMS Winlaisy

Individual views, e.g.company manager Shift Supervisor

Head of department

Access from any web-enabled device, such as scanners, tablets and smartphones ... from anywhere ...

Website, PDF and Excel downloads, Report delivery

Access via web browser (Internet Explorer, Chrome, Firefox, Safari ...) @

PDF

www

40 Making production transparent !

From our diverse project business, we have selected four examples for you – across all industries and standards. From process data acquisition via OPC routers via cockpit and energy monitoring with the Factory Application Server to laboratory manage-ment with WinLaisy and FAS, you gain a small insight into our daily work: "Making production transparent."

projeCtSbde MeS laboratory energy visualization Maintenance qS

Projects

41laboratory management and quality management with FAS and WinLaisy

CuStoMerDP Supply GmbH Beesten is a subsidiary of DP Supply B.V. Emmen, Netherlands. DP Supply develops, markets and produ-ces vegetable-based dry products, such as instant coffee whites, fat powders or whole milk powder substitutes for the food and feed industries.

The development and marketing of the products takes place via the company headquarters in Emmen. The production site is Beesten, where special products are also dried for third parties.

projeCtQuality assurance including data linking with ERP and laboratory systems // Order and product-specific recording of quality values // Assignment to purchase and sales orders // Processing of special orders // Weightnote-Print // Reporting (daily and weekly surveys, orders, quality values)

teChnologyTransfer of the order data from the ERP system // Connection and control of the vehicle scale // Weighing-in, weighing-out // Automatic transfer of the weighing data // Automatic sample generation in WinLaisy including label printing // Manual recording of the determined quality values via web application, allocation to the order // Order-ready notifications and feedback of the quality values from the ERP-system // WinLaisy as a standard-laboratory-system for assay-management and extended processing

Proj

ects

42 production portalEnergy monitoring and system visualization

CuStoMerThe Klingele Group is one of the leading producers of corrugated packaging. The Group has fourteen manufacturing and processing-company worldwide. In Germany, Klingele employs more than 1,000 people and produces more than half a billion square meters of corruga-ted board per year. Individual and inno-vative packaging solutions characterize the Klingele Group.

projeCtEnergy cockpit with meter administrati-on, actual value displays, live chart and Reports, data acquisition from meters // Visualization of production systems and building management // Operating- and visualization-surfaces for the mentioned areas.Project development after the initial phase by the customer himself // Roll-out by "copy & paste" to previously four locations, also by the customer himself

teChnologyFactory Application Server with standard application "Energy Portal" // Further use of the included database and live- charting-modules for process visuali-zation // OPC router for recording with OPC, database, e-mail plug-in // Data storage MS SQL Server

Projects

43

CuStoMerOn the summit Oberscholven in Gelsen-kirchen, the highest artificial elevation of the Ruhr-Area, ELE-Scholven-Wind GmbH set up two wind power plants in 2010 with a capacity of 4.6 mega-watts sufficient to cover the annual consumption of 10,000 people . ELE-Scholven-Wind GmbH is a subsidiary of ELE (Emscher Lippe Energie GmbH) and Mingas-Power GmbH.

projeCtRecording and display of the process values via the database and the web- interface // Monitoring the operating-conditions via the web-cockpit // Assessing the status and performance of responsible employees // Decision sup-port for notifying service from technici-ans or system-builders // Comparison of both systems

teChnologyData transfer of the wind power plants via OPC (XML) // Transfer via OPC router to MS SQL Server // Cockpit-display via Factory Application Server with live dis-plays, charts and gantts // Interpretation of more than 50 different status-types // Cyclic calculation of the statistics in the database // daily e-mail with production figures to the managment staff

Capture the wind ...Cockpit for system monitoring

Proj

ects

44

CuStoMerStadur is one of the largest manufactu-rers for composite elements in Europe. The assortment includes elements for doors, windows and facades, bathrooms and damp rooms, light foam panels for advertising signs and materials for vehicle construction. As a further focus, Stadur also offers custom-made products for yacht building or mechanical engineering.

projeCtDetection of process values and sys-tem status // Wago-controls as measu-red value sensor // Data provision for the economy system (Stadur software development for all planning- and control-functions) // Transfer of set value / control variables from the economy management, e.g. Heating control // Project development and control programming by the customer after inray-training // steadily growing project, currently almost 100 connec-tions

teChnologyOPC router with database and OPC plug-in // Detection via Wago controls // Temporary power measurement with mobile devices, connection via Ethernet to decentralized switches or wireless

Mde with the opC routerProcess values and system status

Projects

Innovation and system solutions

47

Non-food

Food

a selection of our customers

cust

omer

s

inray industriesoftware gmbhHolstenstraße 4025560 Schenefeldphone: +49 (0) 48 92 - 890 08-0fax: +49 (0) 48 92 - 890 08-10e-mail: info@inray.de

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