ProVis - GEWATEC GmbH & CO.KGfile.gewatec.com/www/100_Kataloge/Englisch/50_ProVis.pdf · Machine- and Production Data Acquisition KA T ALOG 060804-0001 ProVis MDA PDA DNC QDA mDA

Machine- andProduction Data Acquisition

www.GEWATEC.com

KA

TA

LO

G 0

60

80

4-0

00

1

ProVis

MDAPDA

DNCQDA

mDAMDA/PDA

Production Visualisation

With PPS-Interface

MDEBDE

Windows XP

Produktion

20.10.09

S*

12:03

DNC

AusschussKorrektur

Auftrag

Wechsel

Kommt

Geht

Rüsten

Produktion

Betriebsmittel

Mehrm.Bed.

Reparatur

Störung

Pause

Warmlauf

Qualität

Material

Personal

Wartung

Erstprüfung

Werkzeug

GEWATEC, headquartered in Wehingen/Germany, has been developing complete solutions for medium-sized companies in the manufacturing industry, the automotive supplier focused machining, plastic injection moulding, and medical technology.

GEWATEC is a strong partner for implementation of complete, modulary structured solutions. Regardless of the objectives GEWATEC developes concepts for installation of integrated data processing systems. From computer-assisted quotation preparation, production planning, machine and production data

GEWATEC.KALK - Machining time computation and quotation calculation GEWATEC.PPS - Production planning and controlGEWATEC.MDA - Machine Data AcquisitionGEWATEC.PDA - Production Data AcquisitionGEWATEC.PMS - Production equipment management, service,

preventative maintenanceGEWATEC.CNC - CNC programming turning, milling, grindingGEWATEC.DNC - CNC program transfer to the CNC controllerGEWATEC.CAQ - Quality AssuranceGEWATEC.IPC - Industrial PC and MDA/PDA terminals

Services:

GEWATEC Academy - Training, consultingGEWATEC Support - Support, service, teleservice

Products: (Info-Line +49 7426/5290-0)

The Informationtechnologist

Verwaltung, Entwicklung, Schulungen, Support

Elektronik, Industrie-PC’s, Netzwerktechnik, Support

acquisition, to quality assurance, the function modules from GEWATEC offer a proven and reliable solution. All modules run autonomously as well as in the Network combination. The interfaces are function proven and are guaranteed to work together. GEWATEC is a single source for the complete solution. This means that you are spared a later finger-pointing wrangle between component suppliers.More than 500 customers in the metal working supply industry are supported by GEWATEC in the selection, implementation, and integration of innovative information technology..

The collaborative path to a solution that satisfies our

customers' requirements:- Precise analysis- Determination of requirementsWorking out integration models

Conception:Many standard components that can be combined in a modular system serve as the basis.

Solutions:After developing hardware and software, the analysis, and careful planning, a solution is produced that meets your requirements

Consulting, training, and support services round out the diverse spectrum.

We increase your productivity!

1000 Questions

Data Aquisition/sensor technology

MDA/PDA Software

General

MDAPDAPDA

DNCQDE

mDA

Quality Data Acquisition

Machine Data Acquisition

Production-Acquisition

Processdata-Acquisition

Mobile direct numeric control

mobileData Acquisition

Machine terminals

Amortizationcalculation

PPS-Interfaces

CAQ-Interfaces

Production equipment management

Capacity planning

Analysis

What you should be aware of

Preventative Maintenance

The answer to 1000 questions in your company

CAQ

KALKCNC

DNC

PPS

IPC MDE

BDE

When is the next Service-date?

How is the process

capability?

Where are the

parts?

How is machine utilization?

How long is the machine still allocated?

Why did the machine fail tonight?

How much material do I still need to order?

What is the actual machining time?How was the last shift?

When will the

parts be ready?

What is the actual return on capital?

Time-Tec1000 QuestionsProVis

??

ProVis....The comprehensive answer of all questions in your Production.

ProVis offers you:

Reduction of the throughput times and delivery timesOptimization of capacity and resource utilizationIncreased productivityTransparency in production planningConcurrent calculationAutomatic final costingImproved weak point analysis

Controller:How can we reduce costs?How high is cost for goods manufactured for this part?What is the average machine capacity utilization for this year?

Production planning:What is the remaining runtime for this order?What are our throughput times per order?

PersonnelMy default value for charging is too low?Which is my next order?

Quality AssuranceAre the specified inspection intervals maintained?Is the process under control?

DP managersWe need a simple interface to our PPS system!Our manual quantity acquisition is uncertain and too complex!Isn't there an automatic production monitoring system?

Some employees spend many hours gathering and evaluating information. The ensuing loss in time, money, and productivity is extremely high.ProVis meets these challenges by making information available at the right place at the right time.

Management:What is the capacity utilization of our plant in Portugal?Can we introduce bonus awards to motivate our employees?

Sales:Can we still make a partial shipment today?Do we have the costs under control for the new part?Do I have a final costing for this production order?Will my customer get his parts on time?

Production manager:What is the capacity utilization of the third shift?I need a current overview of machine allocation!When did this working cycle start?Which cost centre still has free capacity?Why did machine no.12 fail in the night shift?

Purchasing:What is the material requirement for this order?What's the service life like for the new sintered carbide drills?

In order to act successfully in international markets, flexibility, speed, and information about manufacturing processes are important prerequisites.This information as a production factor consistently and increasingly gains in significance. Even in effectively working companies, manufacturing data often are at best still "islands of information".NC programs, test plans, machine data, and production orders are found at various workstations, are gathering dust in file cabinets or flutter over all the desks in the company.

ProVis create order in your company!

1000 questions... that keep your company on tenterhooks

General

1000 Questions

MDA/PDASoftware

Data-Aquisition

Preventative maintenance .

Mach ine-Terminals

CAQInterfaces

Analysis

AmortizationCalculation

What youshould beaware of

Production-Equipment-

Management

Capacity-Planning

PPSInterfaces


MDA/PDA control desk computer

On this computer in network composite the MDA data are collected via the GEWATEC bus system and the ONLINE status of all machines is displayed in real time.All machines are ordered according to product groups and depicted graphically on the screen. If the machine is not producing then this fact is indicated by the status traffic light on the ProVis monitor. In addition to the machine icon the article number, the current machining time, the current malfunction code and the remaining quantity are also shown. The order progress display under the machine image shows the current manufacturing status. Click on the machine with the mouse to display additional information on manufacturing progress. All information is captured and displayed "online" and in "real time".

Final costing, formal printouts

At the end of the last working cycle a formal printout starts automatically which outputs the entire final costing with target/actual comparisons of all working cycles and all material with drawals.

Runtime diagram

The malfunction codes are applied to the time axis in the runtime diagram. This display shows when, which machine, experienced which malfunction.

Intense competition and intense cost pressure compel manufacturing firms to implement transparent, completely monitored, lean production. However lean production can only be realized with a DP solution that is easy to handle.

ProVis is a modern MDA/PDA system that has been developed in object-oriented system architecture with graphic user interface and state-of-the-art client/server technology. With ProVis you are satisfy all requirements placed on modern and demanding manufacturing.ProVis is one of the most important components

ProVis monitor mode

All ProVis control desk information, including the runtime diagram can be called and shown on any PC in the network.

Stamp-Client

The Stamp-Client can run on any PC or on the GEWATEC industrial PCs. The Stamp-Client is used to log orders on and log orders off. Any number of malfunction codes and status messages can be captured and managed. In addition, the smallest orders, and subcontractor's working cycles are also captured and managed on the Stamp-Client. Auxiliary programs such as DNC, CAQ, etc. can be called from the Stamp-Client's user interface.

in the GEWATEC MES solution for medium-sized companies in the manufacturing industry.GEWATEC MES offers the following advantages to the user:

With ProVis GEWATEC offers you an effective instrument for realization of these objectives to keep you a decisive step ahead of the competition.

-Reduction of the throughput times and delivery times-Optimization of capacity and resource utilization-Increased productivity-Transparent production planning-Automatic final costing

ProVis MDA/PDA Software

General

1000 Questions

MDA/PDASoftware

Data-Aquisition

Preventative maintenance

Machine-Terminals

CAQInterfaces

Analysis



Management

Capacity-Planning

Order overview

At anytime open, semi-finished and finished orders can be listed with their associated working cycles and working cycle states.

Order information

ProVis supplies precise information about the order and the associated working cycles at all times. The info window shows the article, information about material consumption, and much more. A calculation that accompanies the working cycle provides information about profit and loss even during machining.

ProVis capacity planning 1)

ProVis not only shows analyses from the past, it also includes a powerful capacity planning tool. Through graphic interaction with the specific working cycles these working cycles can be shifted and rearranged.Capacity bottlenecks are detected at a glance.

1) Only in conjunction with the "KapPlan" capacity planning system.

Analysis

ProVis enables the following analyses:

MachineŸ Detailed machine, machine group, and cost centre capacity utilizations via freely selectable periods or shifts Ÿ Machine runtime diagram online or retroactively for all machines (screen and printer) shift log, with shift performance, order progress, standstill and remaining runtimes, (machine runtime diagram) Ÿ Ghost shift with automatic end (night work) Ÿ Interruption and resumption of ordersŸ Separate analysis of bar stranders/chucking machinesŸ Evaluations of production islands with manual workstations or finish cutting MaterialŸ Material consumption per day, per shift, per order Ÿ Preview of material requirements for the next day or remaining order Ÿ Evaluation according to different materials

Order

Ÿ Order analysisŸ Material/tool consumption and costsŸ Weak point analysis of all standstill times and reasons Ÿ Profitability considerations, value added, group, period

ProVis and CAQ

In conjunction with the GEWATEC CAQ solution, GRIPS, the control desk even monitors the measuring intervals through dynamic sharpness test control. The control prompts the worker to measure by activating a signal light if the inspection interval is exceeded.



PPSInterfaces

Produktion

20.10.09

S*

12:03

Time-TecProVis

TCP/IP (ASCII, ODBC, Binär)

PROVIS

Monitor

Runtime Chart

Z. B. SAP/R3

PPS

AuswertungenReports

AuswertungenReports

SQL-Database

Sybase

SQL-Server

Oracle

Field-Bus

<5 msec

GCC

Capacity Planning

<5 msec <5 msec <5 msec <5 msec

LPT

Wireless

Wireless

V24 Pulse V24TaktV24Pulse

Takt PulseV24

WirelessEthernetProfi-Bus

<5 msec

Data entry/Sensor technology

IC 1100

PQRS

8 9

ENTER

4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

Takt

Status

Bus

ESC BS

K1

K2

0-+/

*

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alog

ger D

L-90

0

IC 900-10

PQRS

8 9

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4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

ESC BS

0-+/

*

.,\

Kommt Geht

Shift

F8

F7

F6

F5

F4

F3

F2

F1

Bus Kom In1 In2 In3 In4 Count

Gildemeister

Produktion

Werkzeugbruch

Materialmangel

Stromausfall

Qualität

Reinigen

Wartung

Personal

GEWATEC IC800

41245

IC 900

PQRS

8 9

ENTER

4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

Takt

Status

Bus

ESC BS

K1

K2

0-+/

*

.,\

PRS

8 9

ENTER

4 5 6

1 2 3

0

TUV WXY

MNJKLGHI

OQZ

#-? ABC DEF

ESC

IC 1100

PQRS

8 9

ENTER

4 5 6

1 2 3

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MNOJKLGHI

ABC DEF

Takt

Status

Bus

ESC BS

K1

K2

0-+/

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IC 900-10

PQRS

8 9

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4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

ESC BS

0-+/

*

.,\

Kommt Geht

Shift

F8

F7

F6

F5

F4

F3

F2

F1


Gildemeister

Produktion

Werkzeugbruch

Materialmangel

Stromausfall

Qualität

Reinigen

Wartung

Personal

GEWATEC IC800

41245

IC 900

PQRS

8 9

ENTER

4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

Takt

Status

Bus

ESC BS

K1

K2

0-+/

*

.,\

PRS

8 9

ENTER

4 5 6

1 2 3

0

TUV WXY

MNJKLGHI

OQZ

#-? ABC DEF

ESC

IC 900

PQRS

8 9

ENTER

4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

Takt

Status

Bus

ESC BS

K1

K2

0-+/

*

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IC 900

PQRS

8 9

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4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

Takt

Status

Bus

ESC BS

K1

K2

0-+/

*

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IC 1100

PQRS

8 9

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4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

Takt

Status

Bus

ESC BS

K1

K2

0-+/

*

.,\ Dat

alog

ger D

L-90

0

Ethernetor

Wireless

Ethernetor

Wireless

Ethernetor

Wireless

Profi-Bus

Produktion

20.10.09

S*

12:03

General

1000 Questions

MDA/PDASoftware

Data-Aquisition


Machinn-Terminals

CAQInterfaces

Analysis



Management

Capacity-Planning

MoldingMolding

StampingStamping

INDUSTRIEELEKTRONIK GmbH

Ethernet

TurningTurning

ProVis sensor technology

ProVis records events in production where they occur. Whether bending/curving machine, CNC machine, machining centre, or manual workstation, the machine states, and quantity cycles are sampled and electronically analysed in accordance with state-of-the-art concepts. GEWATEC is more than 10 years of experience in networking computers together with CNC machines, scales, and test instruments guarantees data communication reliability and security.

Runtime diagram:

The malfunction codes are applied to the time axis in the runtime diagram. This display shows when, which machine had which malfunction.

MillingMilling

Unidor Controller

The Unidor controller supplies all machine states to the MDA/PDA control desk from ProVis.



PPSInterfaces

IC 1100

PQRS

8 9

ENTER

4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

Takt

Status

Bus

ESC BS

K1

K2

0-+/

*

.,\ Dat

alog

ger D

L-90

0

IC 900-10

PQRS

8 9

ENTER

4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

ESC BS

0-+/

*

.,\

Kommt Geht

Shift

F8

F7

F6

F5

F4

F3

F2

F1


Gildemeister

Produktion

Werkzeugbruch

Materialmangel

Stromausfall

Qualität

Reinigen

Wartung

Personal

GEWATEC IC800

41245

IC 900

PQRS

8 9

ENTER

4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

Takt

Status

Bus

ESC BS

K1

K2

0-+/

*

.,\

PRS

8 9

ENTER

4 5 6

1 2 3

0

TUV WXY

MNJKLGHI

OQZ

#-? ABC DEF

ESC

IC 900

PQRS

8 9

ENTER

4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

Takt

Status

Bus

ESC BS

K1

K2

0-+/

*

.,\

PRS

8 9

ENTER

4 5 6

1 2 3

0

TUV WXY

MNJKLGHI

OQZ

#-? ABC DEF

ESC

Produktion4711

10543

S*

4712

IC 900

PQRS

8 9

ENTER

4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

Takt

Status

Bus

ESC BS

K1

K2

0-+/

*

.,\

Time-TecProVis

TC

P/IP

(A

SC

II, O

DB

C, B

inär)

TCP/IP

TCP/IP

MDA

Euromap63

Euromap 63-Interface

Euromap63

PDA

TCP/IP

Euromap63

TCP/IP

CAQ

CAQ

Molding

Datalogger

TC

P/IP

(A

SC

II, O

DB

C, B

inär)

Z. B. SAP/R3

PPS

CAQ

AuswertungenReports

Monitor

Qualitätsregelkarten

AuswertungenReports

SQL-Database

Sybase

SQL-Server

Oracle

MDA

PDA

MDA/PDA

TCP/IP

TCP/IP

CAQ

CAQ

TCP/IP Euromap63

Turning/Milling

ProVis

Machine and Production Data Acquisition

EUROMAP 63

EUROMAP 63 is a standardized file-sharing based interface that is especially designed for communication between a master computer and injection moulding machines. The data is exchanged via command files that are written by the master computer and read by the injection moulding machine. After execution of the commands the injection moulding machine sends the requested data to the master computer. The data exchange is synchronized by alternately writing and deleting question and answer files. With this interface all injection moulding parameters, such as pressures, times, and temperatures can be set and monitored. Moreover it is possible to load or unload complete tool data records. Thus the start-up speed of a changed tool is significantly reduced. The Euromap 63 interface is an important tool for controlling and monitoring injection moulding machines.

General

1000 Questions

MDA/PDASoftware

Data-Aquisition


Machine-Terminals

CAQInterfaces

Analysis



Management

Capacity-Planning

TC

P/IP

(A

SC

II, O

DB

C, B

inär)

PROVIS

Monitor

Runtime Chart

TCP/IP

GEWATECBDE-Licence

GEWATECBDE-Licence

Stanzen

Z. B. SAP/R3

PPS

AnalysisReports

AuswertungenReports

SQL-Database

Sybase

SQL-Server

Oracle

* 1500 Hub/min* no Debouncing necessary

<5 msec

The Signal from the Unidor-Control

GEWATEC Bruderer-Client

ProVis can obtain manufacturing data directly from the Bruderer machine controller. This is possible thanks to an interface provided by Bruderer.The following information is read from the controller: Production status still/running, quantities, stroke/min and automatic codes for standstill. In addition the GEWATEC Bruderer Client has functions such as working cycle check-in and report manual standstill codes.



PPSInterfaces

UnidorMDE

SoftwareLizenz

BRUDERER

CertificatedBruderer-Interface

In March 2003 the ProVis was tested for execution as agreed and the certificate for conformant integration of the operator prompting was issued. Thus the function can be visualized in the operator panel of the BRUDERER B-controller.

Functional security and reliability of complex equipment and manufacturing resources, and thus availability of this equipment and these resources can be maintained at a uniform high level of productivity with a consistent preventative maintenance concept.Cost reduction, higher efficiency, and increase in machine availability and replacement part availability are the requirements imposed on modern production equipment management. Systematic weak-point analysis and prevention are of central significance. The required maintenance measures are harmoniously integrated in the manufacturing process with PMS from GEWATEC.

ServicePreventative maintenance

Production equipment overview

The production equipment can be sorted as desired according to column headers.The respective status of the production equipment is color coded.

Production equipment master data list

The specific data are created the master data list of production equipment.Number, designation, maintenance schedules etc.

Intelligent part list logic

Assignment of components and service schedules via the part list.

Time-TecProduction equipment managementProVis

Execution of service schedules

Production equipment that is due for service is checked according to the specifications of the stored service schedules. The worker is prompted through the individual service guidelines.After service has been performed successfully the status of the production equipment is automatically reset to "Ready" status. After unsuccessful execution of the service schedule the user has the possibility of assigning an appropriate status.

Execution of unscheduled service

Unplanned service is documented and can be tracked at anytime via the PMS history. Damage symptoms provide information about the momentary status of production equipment. Duration and cost of the unplanned service are captured concurrently.

Cost finding and consumption data

The acquisition of different cost items enables analysis of the production equipment from economic perspectives.

Schedule monitoring

The automatic schedule monitoring function provides an overview of all future maintenance tasks.

Service and inspection history

Service tasks are documented and can be tracked at anytime via the PMS history. In addition service tasks are recorded in the Event Writer from ProVis and displayed in the runtime diagram of the respective machine.

General

1000 Questions

MDA/PDASoftware

Data-Aquisition


Machine-Terminals

CAQInterfaces

Analysis



Management

Capacity-Planning



PPSInterfaces

Capacity Planning is a convenient control desk system for application planning of manufacturing resources - machines and personnel. With KapPlan allocation and utilization of all machines, workstations, and departments is clearly displayed. All working cycles of the production orders are displayed over the time axis with consideration of the calendar.

Forward schedulingBack schedulingCapacity displayPDA couplingPPS coupling

t-1

t+1

t0

heutemorgen

gestern

drehen

fräsen

bohren

Traub 1IndexStarHermle 1

drehen

fräsen

drehen

fräsen

drehen

drehen

heute

Hermle 2

Traub 2

schleifenschleifenschleifen

PeTeWe

Capacity graphs, resource utilizationOn the left screen border the free capacity of the individual manufacturing resources over the currently selected time period is shown in the form of a capacity graph. The color of the capacity bar changes to red if capacity is exceeded.The top-most capacity bar shows the average free capacity of the entire machine group.

Capacity bottlenecksIf delivery dates are exceeded then working cycles are displayed in red.Working cycle overlap isindicated by a red frame..

With Capacity Planning your production capacities are completely under control. The graphic planning board enables effortless "drag & drop" shifting of working cycles. Comparable to an early warning system, capacity bottlenecks are displayed immediately. Free capacity can be optimally utilized. Zoom functions enable adjustment of any time window desired. Working cycles can be shifted over various workstations and departments.

Resource requirements And resource supply

for charging and operating machines

Time-TecCapacity PlanningProVis KapPlan

PPS interfaces

KapPlan gets its order data from a PPS system in practical application. Interfaces to the major PPS systems are available.

Calendar

The calendar is the basis for calculating the start and finish dates of the working cycles. Freely definable shift models are assigned to the individual machines.The respective shift models are entered in the calendar.

Production order

The program is based on phased production. For each production order the associated working cycles are displayed in temporal sequence one below the other. The subsequent working cycle can only start when the preceding working cycle has been concluded, or if the specified correlation has been achieved. The individual working cycles can be moved on thetime axis per drag & drop. The subsequent working cycles of the production order are automatically moved back if there is possible overlap.

Order information

ProVis supplies precise information about the order and the associated working cycles at all times. The info window shows the article and the order data that belong to the respective working cycle.

KapPlan reporting

KapPlan enables extensive reportings relative to workstations and manufacturing resources. The capacity graph compares relative machine assignments and shows free capacity.

Additional features

- Graphic display of the personnel situation (Personnel requirements and personnel supply)- Production recommendations- Automatic scheduling of working cycles or of complete PO's on free capacities- Planning of the machining sequences in table form - Dynamic grouping- Multiple working cycles can be moved in one block Target-actual manufacturing comparison

General

1000 Questions

MDA/PDASoftware

Data-Aquisition


Machine-Terminals

CAQInterfaces

Analysis



Management

Capacity-Planning



PPSInterfaces

GEWATEC industrial computers are the most important connecting link between man, machine, and computer. They are used when CNC programs transfer, machine states are captured, quantities are counted, or when test instruments are connected. With an entire family of industrial computers GEWATEC provides the user with a comprehensive information system for Ethernet-based production. GEWATEC industrial computers, in their attractively designed and robust housing with oil-resistant operator panel, have interfaces for an external PC keyboard or a barcode reader, momentary contact foot switch, Ethernet connection, and much more.

MDA quantities

MDA malfunction code acquisition

MDA machine still/running

PDA messages

Barcode reader

DNC program transfer

IC 900-10

PQRS

8 9

ENTER

4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

ESC BS

0-+/

*

.,\

Kommt Geht

Shift

F8

F7

F6

F5

F4

F3

F2

F1


Gildemeister

Produktion

Werkzeugbruch

Materialmangel

Stromausfall

Qualität

Reinigen

Wartung

Personal

GEWATEC IC800

41245

IC 1100

PQRS

8 9

ENTER

4 5 6

1 2 3

TUV WXYZ

MNOJKLGHI

ABC DEF

Takt

Status

Bus

ESC BS

K1

K2

0-+/

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.,\ Dat

alog

ger D

L-90

0

IC900/IC1100

The GEWATEC IC900 industrial terminal is the consistent further development of the IC800 profibus terminal. 12 freely definable function keys enable input of 24 malfunction codes in double assignment. The numeric input block enables production order login and logout.

The IC900/IC1100 has a wireless connection control desk computer. As opposed to the IC900 the IC1100 is equipped with a Linux computer and can be integrated in existing WLAN systems.

- Display 4*20 characters - Wireless (range 200m)

IC-800 malfunction code terminal

The IC-800 malfunction code terminal has been developed for cost-effective acquisition of machine states, malfunction codes, and quantities. Up to 16 freely definable malfunction codes can be acquired and reported to the MDA control desk. The IC-800 is connected to the control desk via Siemens Profibus.

Features

16-freely definable malfunction code keys 1 integrated relay 6-digit display for quantity display

wireless

wireless

Time-TecMachine-TerminalsProVis

PRS

8 9

ENTER

4 5 6

1 2 3

0

TUV WXY

MNJKLGHI

OQZ

#-? ABC DEF

ESC

wireless

IC 900

PQRS

8 9

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4 5 6

1 2 3

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Takt

Status

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Personalzeitkommt/geht

20.10.09

S*

12:03

Produktion

20.10.09

S*

12:03

The IC-3000 is an industrialized, 100% compatible PC in a robust IP54 protective housing (front side IP64)

Processor: Pentium III 800 MHZRAM: 128MB (can be upgraded to 512 or 1GB)Interfaces: 2 x RS232

1 parallel interface PS/2 for optional mouse/keyboard/barcode reader

LAN: Ethernet LAN 10/100 Mbit or WLAN 2 x USB interfaces

Operating system: WIN2000 or WIN-XP Keyboard: PC compatible membrane keyboard Display: VGA 15” color display 1024x768 Mouse: Touch screen display optional

Dimensions: Wall-mount housing: WxHxD: 410 x 387 x 115 Stand: WxHxD: 410 x 420 x 1420

With these features this unit is a multi-functional hardware component in production for:

* PDA: Order data acquisition via barcode or keyboard * MDA: Acquisition of machine states and counting functions * PTA: Personnel time acquisition * DNC: Direct transfer of CNC programs * CAQ: Measurement data acquisition for statistical process control * PPS: Acquisition of stock postings and costs, scale

IC3000

Ethernet-Cable CAT5e

(max. 150 m)

Maximal ComputerserviceNo Heatproblems

The IC-3000 Panel-PC consists of an industrialized operator panel (IP64) with membrane keyboard, (standard PC keyboard), VGA display (15" color display 1024 x 768) and touch screen.

The CPU is separate and is connected to the CPU via the standard interfaces (BGA, KBD, USB/RS232). The maximum cable length for this connection is approximately 2m.

Panel-PC

wireless

General

1000 Questions

MDA/PDASoftware

Data-Aquisition


Machine-Terminals

CAQInterfaces

Analysis



Management

Capacity-Planning



PPSInterfaces

Time-TecCAQ-InterfacesProVis

CAQ-Lamp-Control

Pulse (24V)

State(down/active 24V)

Determination of the number of pieces

Placing of the lamp

by getting the

Quantities in the

inspection intervalin the

quality control plan

Number of pieces timeof the machine

In the test schedule the test interval is specified which prescribes the chronological sequence of the test. The test interval can be entered in "Parts/Hour" or in "Piece".After reaching the specified interval the MDA control desk automatically switches on the test light which then prompts the user to test.The test light is only reset if the sample has been measured on a CAQ test station for the associated test. (See chapter CAQ Grips)

Test schedule with test interval

Checklamp

Produktion

20.10.09

S*

12:03

Testinterval

General

1000 Questions

MDA/PDASoftware

Data-Aquisition


Machine-Terminals

CAQInterfaces

Analysis



Management

Capacity-Planning

ProVis Vers. 3.3.1505The core ProVis functions in overview

Industries

! Mass production! Injection moulding

Benefits

! Increased productivity! Reduction of throughput times and delivery times! Optimization of capacity and resource utilization! Production transparency! Weak-point analysis! Process monitoring

Data acquisition with and without terminal

! Data transfer without cable! Machine status! Quantity! Temperature Planning! Online capacity planning! Calendar for each machine! Calculation! Concurrent calculation! Automatic final costing! Final costing ! Per article! Per production order

Machine

! Runtime online ! Runtime diagram! Traceability Zoom function

Analyses! Order overview! Active orders! Open orders! Semi-finished orders! Finished orders! Order progress! Personnel overview! Article analysis! Machine analysis! Machine analysis- shift! Target/actual analysis! Utilization- shift! Shift evaluation- overall! Shift log! Shift performance! Target/actual utilization- overall! Parts tracking! Analysis according to! Machine groups! Cost centres! Utilizations! Freely selectable periods ! Freely selectable shifts! Standstill times! Remaining runtimes! Ghost shift! Gross cycle time ! Night work! Order interruption! Bar stranders/chucking machines! Islands of production! Manual workstations! Finish cutting! Material consumption! Per shift! Per order! Material requirements preview! Material consumption! Materials! Tool consumption! Weak-point analysis! Standstill times and reasons ! Yield considerations! Value added ! Period! Per machine! Group! TARGET/ACTUAL comparison ! Production! Charging ! Quantity

Personnel

! Personnel requirements- charging! Available personnel Interfaces to all major PPS systems

CAQ interface

! Optical test prompt! Online statistics! Automatic test order generation

Other Interface

! Telephone system! Personal paging system! Activation of LED indicator strip



PPSInterfaces

Analyses and Reports after customer wish

Time-TecAnalysisProVis

ProVis enables the following standard analyses:

Machine

Ÿ Detailed machine, machine group, and cost centre utilizations via freely selectable periods or shifts Ÿ Machine runtime diagram online or retroactively for all machines (screen and printer) shift log, with shift performance, order progress, standstill and remaining runtimes,(machine runtime diagram) Ÿ Ghost shift with automatic end (night work) Ÿ Interruption and resumption of ordersŸ Separate analysis of bar stranders/chucking machinesŸ Evaluations of islands of production with manual workstations or finish cutting

Material

Ÿ Material consumption per day, per shift, per order Ÿ Preview of material requirements for the next day or rest of the order Ÿ Evaluation according to different materials

Order

Ÿ Order evaluationŸ Material/tool consumption and costsŸ Weak-point analysis of all standstill times and reasons Ÿ Yield considerations, value added per machine, group, period Ÿ Automatic final costing per article/production order Ÿ TARGET/ACTUAL comparison of production and charging Ÿ Calculation of gross cycle time Ÿ Transfer to PPS system for final costing Ÿ Final costing of a PO with TARGET/ACTUAL comparison

General

1000 Questions

MDA/PDASoftware

Data-Aquisition


Machine-Terminals

CAQInterfaces

Analysis



Management

Capacity-Planning



PPSInterfaces

Savings potentialComputation factors Example Your Investment

Increased production A 5 % ___________________________Hourly machine rate (€) B 45,- ___________________________Workhours per day C 8 hours ___________________________Workdays per year D 200 days___________________________

Number of machines E 20 ___________________________

Savings per day in € F 360,- ___________________________(F = A * B * C * E)

Savings per year in € 72.000,- ___________________________(F * D) Your Savings per year

Amortization calculationSavings potential Example Computation factors

(in €)Terminalcosts per Machine A 500,- ___________________________Installation costs per Machine* B 250,- ___________________________Networking costs per Machine* C 750,- ___________________________Internal costs (Selection phase)* D 10.000,- ___________________________2 evulation monitors (PCs) E 5.000,- ___________________________MDA/PDA Software F 12.500,- ___________________________PPS Interface G 2.500,- ___________________________

Number of machines H 20 ___________________________

(A*H)+(B*H)+(C*H)+D+E+F+G = 60.000,- ___________________________Your Investment

Amortization

The amortization is calculated from the capital expenditure and savings per year.

Amortization of your system

Capital expenditure--------------------------------------------------------------- = _____________ YearsSavings per year

Example: Capital expenditure 60.000,--------------------------------- = ----------------------- = 0,83 Years (approx 10 Months)Savings per year 72.000,--

* Installation costs: For the installation costs small parts such as cable, relays, power supplies, terminal holders, etc. are specified.

* Networking costs: For the networking costs the costs of the electrician are specified (networking the individual terminals)

* Internal costs: Internal costs can be personnel costs for example, that can be incurred in the process of selecting a system.

(Vendor comparison).This is where costs can also be specified that can be incurred when introducing the system until release.

Savings and Amortization from a MDA/PDA System

Time-TecAmortization calculationWhat you should be aware of

ProVis

What you should be aware of when introducing an MDA/PDA system

Each MDA/PDA system with its analyses is only as good as the data that is input. No matter how much automation is involved in data acquisition, the MDA/BDA system lives from the input data.

The quality of the data is the crucial factor, not just the quantity.

With introduction of an MDA/PDA system the organization and administration will be adapted to modern organization forms.MDA/PDA systems should not be deployed against the worker, rather they should be used to optimize the operating procedure and to indicate weak-points. Firms with a works council should address these issues in planning.MDA/PDA systems do not replace the dialog between the planning level and production.

The abuse of personal data can be excluded from the technical program side.MDA/PDA systems should be amortized within one to two years.

ABASAgilisysApolloAxaptaBäurerBrainGPPSIFAXInforINFRANavisionSAP/R3SAP Business one

PPS-Interfaces:(To the major ERP/PPS systems)

General

1000 Questions

MDA/PDASoftware

Data-Aquisition


Machine-Terminals

CAQInterfaces

Analysis



Management

Capacity-Planning

PPS-Interfaces

Production orders

ProVis gets the production order data from a PPS system. The data can be read directly via a file interface, or directly from the external database via ODBC. The information exchange can be individually tailored via the freely configurable interface.If corrections of existing working cycles are transfer from third-party systems, then these corrections will also be applied.

Production acknowledgements

A production acknowledgement to the third-party system is executed at the start of the working cycle, end of the working cycle, and when the shift changes. The information that should be acknowledged can also be freely configured. Pieces and times can either be specified absolute or relative to the last message.The acknowledgements to the third-party system are executed via the same communication paths that are used for swapping-in the production order data.



PPSInterfaces

Quotation calculationMachining time calculationProduction Planning and ControlCapacity planningMachine Data AcquisitionProduction Data AcquisitionProduction Equipment ManagementQuality management DNC program transfer

MES solutions for the medium-sized manufacturing company


www.GEWATEC.com

ERP

CALCMDA

PDA

IPC CNC

DNC

CAQ

Central Office78564 WehingenGroz-Beckert-Str. 4Tel. (+49) 07426 / 5290-0Fax. (+49) 07426 / 5290-10E-mail: [email protected]

Sales partner

Email: m

Mongkol Engineering Hougang Central Post Office P.O. Box 343 SINGAPORE 915312

[email protected]

Documents

ProVis - GEWATEC GmbH & CO.KGfile.gewatec.com/www/100_Kataloge/Englisch/50_ProVis.pdf · Machine- and Production Data Acquisition KA T ALOG 060804-0001 ProVis MDA PDA DNC QDA mDA