The rapid worldwide development in the production sector called for a proper planning, calculation, sharing and collection of production data. In line with this requirement, MRP, MRP2 and ERP were developed, respectively. The next stage has been the development of intermediate systems called MES (Manufacturing Execution Systems") which have been designed to help develop and execute production plans that are decided upon during production planning. These systems aim to receive and/or send data directly from and/or to the machines. To that effect, a bi-directional flow of data is targeted between the machine and ERP. Values that can be measured electronically are obtained through necessary sensors, eliminating the chance of user fault. It is likely that the behaviour exhibited by electronic motors, controls and also machines during operation can be changed according to certain data transmitted to production from ERP system. When MES systems are not used, such data are transmitted by the production staff via a computer or a paper-based process, most of the time resulting in delays.
CANIAS ERP has inside a MES (Manufacturing Execution Systems) system that is called the Automation Module. It directly communicates with PLC devices that are connected to the machines in the production unit. The application running on PLC has also been developed to be compatible with CANIAS ERP. Objectives of the automation module:
Conducting, via the Machine, those operations carried out by the production staff in Production, Maintenance and Quality Control modules of CANIAS ERP through PLC.
Managing Machine functions through PLC over CANIAS ERP (automatic setting of machine settings according to parameters specified in ERP system, switching the machine to serial mode, turning off the Machine, modifying Mould characteristics, etc.)
Ensuring that production is watched live. Ensuring that problems that occur during production are viewed instantly, production losses are minimized.
Calculating workbench efficiency properly using TEEP, OEE, and ensuring that necessary recovery work is properly carried out. BOM (Product Tree), ROU (Route) data are updated in the light of live data. Ensuring that personnel performance is measured and necessary arrangements are provided for.
Collecting data in relation to unscheduled downtime, determining cause and duration of downtime, and minimizing downtime periods after a proper analysis.
Managing the periodic maintenance of the machine over PLC, minimizing loss of use on the machine (frequency of faults and maintenance/repair cost), thereby improving efficiency.
The most important objective of the automation module is to collect maximum data with minimum input by the user. To enable minimum data input by the user, data are also transmitted automatically from barcode readers and several measuring instruments connected to the machine to those fields in which the user can input data. As a result, production staff will not lose time with input of data and at the same time erroneous data input by the user will be avoided.
Machine parks owned by businesses include different features. In general, we can gather them under 3 groups: I. Different machines performing the same task, II. The same machine performing different tasks, III. Machines performing the same task. It is not reasonable that all the machines in a business are managed with the same logic (same PLC software). For example, a profile cutting machine and a packaging machine do not have the same management parameters and do not perform the same tasks. These cannot be managed with the same PLC software, or even so, superficial data can be displayed and collected, but data specific to the production stage cannot be used. While one might want to adjust automatically the length to be cut by the cutting machine, the packaging machine does not have such a parameter. The signals that communicate the failure of the packaging machine may be different than those of the profile cutting machine. While the cutting machine may permit the worker to set production speed manually, the packaging machine may retrieve a speed used in previous productions from ERP system, or prompt PLC to adjust it. In CANIAS ERP automation module, the features and production tasks of the machines in the machine park owned by the business are analyzed deeply with the aim to make additional developments in the standard PLC program already available to best suit the process. Accordingly, an automation system that fully meets the requirements of the business can be established in minimum time with minimum cost. Additionally, all the source codes and development kits are made available to the user company for examination and revision purposes.
Let us familiarize ourselves with the features of CANIAS Automation Module in general.
Staff Input Screen
It is ensured that the machine is operated by the right staff. Thereby, it is prevented that the machine is not operated by the wrong staff, avoiding possible faults and ullage that might otherwise occur. If any periodic maintenance has been assigned to the machine, it is reminded that maintenance should be performed by the staff. Faults arising from such failure are minimized. Machine efficiency is improved. In CANIAS ERP system, after the right staff data are input, the jobs on the machine are caused to be transferred to the Machine In Setup, In Production, or In Downtime screen in line with the tabulation results. If there is no outstanding operation on the machine, the next operation in the schedule (Setup, Production) can be started automatically at the operator's discretion. These are instant data and are read directly from CANIAS ERP system without using any middleware.
Job Order Search Screen
The staff member is enabled to view existing jobs assigned to the machine and the status of such jobs (Setup, Production). Searches can be conducted amongst job orders. He is allowed to see a list of the raw materials to be used for the job order and their warehouse stock status. The staff member can start a suitable job order. If the staff member has no authority to choose a job order, he compulsorily starts the first job order in the schedule.
Setup and Production Screens
In line with the data supplied from the machine, Operation Time, Production Quantity, Temperature data, Speed data, Fault signals and similar data that can be derived from the machine can be evaluated. It generates sound or light signals to the staff member according to the requirements of the business. For example, if the machine is running slower or faster than required or machine temperature is lower or higher than required, sound or light alerts are generated to warn the staff member in charge. Thereby, necessary measures are caused to be taken immediately and likely faults and loss of use are minimized. Ullage and re-processing quantities that arise during production can be kept properly, and the actual raw material quantity that has been used in production can be transmitted to the system. As a result, quantity and time updates related to Product Tree and Route are handled with actual data.
Downtime Screen
It enables to keep data to be supplied from the machine such as machine Downtime or the stoppage time when the machine fails, quantities produced up to downtime, downtime or fault code, and whether a fault report has to be prepared or not. As a result, fault or downtime data for the machine are properly stored and allow making necessary analyses.
Production and Performance Monitoring Screen
It enables to instantly monitor the production status. There are indicators showing machine status, instant production quantities and operation speeds. Machine Status, No Job in Schedule (Empty), Start Setup, In Setup, Start Production, In Production, In Downtime, machine operation speed (Slow, Normal, Fast). Thereby, managers are instantly supplied with proper data, and allowed to take necessary measures as practicably as possible, minimizing losses of use, and improving performance.
As a result, quantity and time updates related to Product Tree and Route are handled with actual data.
