According to Omron the business environment is reliant on accurate and timely information, with operational decisions being made based on this information acquired on a continuous basis. MES – manufacturing execution systems now bridge the information gap and improve the way organisations run their manufacturing facilities, matching input requirements to market demand.
Critical data is collated and stored
Production departments plan using data gathered from this system, areas of particular interest include:
* Machine efficiency data – this assists in accurate matching of production to the forecasted demand.
* Rejection and wastage reports – which product line run best on which machines. Is maintenance required as there is high wastage?
* Reason for downtime – how long was the machine standing idle? What was the reason?
* Track and traceability – makes it possible to pin point the operator, shift, raw material supplier and specific batch of products. Recalls are less problematic. Data can be analysed further to ensure systems are in place that ensure consistency in product quality and performance.
The challenge is to design a reliable system that acquires real-time data and is easy to maintain. The system must also be open to all the organisation’s networks. First consider the design of the data collection network, this usually gets allocated to the IT department and inevitably a PC-based system is installed. In itself, this is not a problem as PC-based systems have proved their place in the industry, but the moment the different programming languages are considered it becomes obvious that dedicated personnel are required to maintain these systems.
Next, consider the process control networks, set-up and maintained by the engineering department. It is where these two worlds collide that chaos usually ensues. Ideally both systems should be maintainable by the same personnel, preferably those that look after process control.
Omron offers a system based on open communication that has proven to be successful. Its success is based on the ability to get process data to an SQL, MSACCESS or just a simple CSV layer reliably. Drivers to communicate with most major scada systems are already built-in and additional software can be offered for OPC functionality that allows interfacing with virtually any higher level application.
The basic systems allow collection of data from the factory floor without the need to replace the existing control system. The set up allows for parallel interfacing with I/Os or where there are current networks in place it offers masters that become part of these existing networks. Communication can be via DeviceNet, Profibus, Ethernet/IP, Modbus, Componet, Profinet as well as other options.
The system allows Omron to offer turnkey solution from factory floor data collection through implementing a scada system and, if required, full MES functionality. This allows the customer to deal with one party from shop floor to top floor.
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